MOSCOW, Russia / AsiaWire.IO / – Researchers from Russia and China have created an ultrasonic welding technique that enhances the strength of metal connections by two times, TV BRICS reported. The report referenced South Ural State University, or SUSU, whose scientists collaborated with Chinese partners on this project. This new method also extends the lifespan of welded parts by 1.9 times, offering a more reliable way to join metals with different characteristics, such as steel and aluminium.
The challenge of welding steel and aluminium together has persisted for years. When these metals are joined, brittle intermetallic layers often develop at the interface. Such hard layers can become stress points, compromising the joint’s durability under load. The innovative technique aims to minimize these weak spots and reduce the likelihood of fractures. SUSU is based in Chelyabinsk, Russia.
During spot welding, the team applied ultrasonic vibrations of approximately 1,200 watts. This vibration directly influences the metal as the joint is formed, altering its microstructure. According to the scientists, this process refines the metal’s crystal structure and decreases the crystal size by nearly five times. Local media in Chelyabinsk first reported on this research earlier in October.
Denser welds exhibit greater resistance to vibration and stress
The ultrasonic process also reduces the thickness of the brittle intermetallic layers by half. It eliminates air pockets within the weld, resulting in joints that are denser and more resistant to mechanical stress. Testing revealed that the strength of these joints doubled using this new approach. Additionally, the lifespan of the welded parts increased by 90%, matching the 1.9-fold improvement noted by SUSU. The researchers believe these enhancements could improve resistance to prolonged vibration and mechanical pressure.
These findings suggest significant advantages for components subjected to continuous movement and heavy loads. According to the university, joints treated with this ultrasonic method can endure ongoing vibrational forces for extended periods without cracking. Such durability is crucial for vehicles and aircraft, where parts are repeatedly stressed during operation. The results were shared by the university and reported through TV BRICS.
Enabling lighter construction for vehicles, aircraft, and infrastructure
The scientists indicated that this technology has potential applications across the automotive, aerospace, and construction sectors. Using steel and aluminium together allows manufacturers to design structures that are both lighter and stronger. The university pointed out that lightweight frames for electric vehicles could be one of the key uses. In aviation, combining aluminium and steel components can contribute to reducing the overall weight of aircraft structures.
This project exemplifies ongoing scientific collaboration between Russian and Chinese researchers. Developing stronger joints between dissimilar metals can enable the production of lighter yet more durable parts. The technique could facilitate the creation of structures that leverage steel’s strength alongside aluminium’s low weight. The reports did not specify details regarding commercial implementation of this method.