MOSCOW, Russia / AsiaWire.IO / – A collaborative effort between scientists from Russia and China has resulted in an innovative ultrasonic welding method that enhances the strength of metal connections by 2 times, according to TV BRICS. The development was carried out by South Ural State University, or SUSU, in partnership with Chinese researchers. This approach also extends the lifespan of welded parts by 1.9 times, offering improved reliability when joining metals with different characteristics, such as steel and aluminium.
For a long time, welding steel to aluminium has been a significant challenge for industry. The formation of brittle intermetallic layers at the joint can occur during welding, creating zones of stress concentration that weaken the connection under load. The new ultrasonic technique aims to minimize these weak points, thereby reducing the likelihood of fractures. SUSU is located in Chelyabinsk, Russia.
The researchers applied ultrasonic vibrations of approximately 1,200 watts during spot welding. These vibrations directly influence the metal as the joint forms, leading to changes in the weld’s structure. The team reports that this process refines the metal’s crystal structure and decreases crystal size by nearly five times. Local media in Chelyabinsk first reported on this research earlier in October.
Denser welds resist vibration and mechanical stress better
Ultrasonic treatment also reduces the thickness of the brittle intermetallic layers by half and helps eliminate air bubbles within the weld. This results in joints that are denser and more resistant to damage. Testing demonstrated that the strength of welded joints doubled using this method, and the service life of the components increased by 90%, matching the 1.9-fold improvement noted by SUSU. The researchers believe these advancements could improve resistance to long-term vibration and mechanical forces.
The findings suggest significant benefits for parts subjected to continuous movement and high loads. According to the university, joints treated with this ultrasonic process can endure prolonged vibrational stresses without cracking. This durability is particularly relevant for automotive and aerospace applications, where components face repeated operational stresses. The results were shared through TV BRICS and reported by the university.
Enabling lighter designs for vehicles, aircraft, and construction
The scientists indicated that this technology could find applications across automotive, aerospace, and construction sectors. Combining steel with aluminium allows manufacturers to create lighter structures without sacrificing strength. The university highlighted the potential for lightweight electric vehicle bodies as a promising area. In aviation, joining aluminium and steel components could help reduce overall weight of aircraft structures.
This project exemplifies ongoing scientific collaboration between Russian and Chinese researchers. Improved joints between dissimilar metals could enable the production of lighter, more durable components, supporting structures that leverage steel’s strength and aluminium’s low weight. The reports did not specify plans for commercial application or deployment.