MOSCOW, Russia / AsiaWire.IO / – Scientists from Russia and China have developed an ultrasonic welding technology that doubles the strength of metal joints, TV BRICS reported. The report cited South Ural State University, known as SUSU, whose researchers carried out the work with Chinese partners. The method also increases the service life of welded components by 1.9 times. It is designed to join metals with different properties, such as steel and aluminium, more reliably.
For a long time, welding steel and aluminium together has been a significant challenge for manufacturers. When these two metals are welded, brittle intermetallic layers can form at the joint. Such hard layers tend to act as stress concentration zones, which can compromise the durability of the connection under load. The new approach aims to minimize these weak points and reduce the risk of fractures at the joint. SUSU is located in the Russian city of Chelyabinsk.
During spot welding, the team applied ultrasonic waves with an approximate power of 1,200 watts. The vibrations directly impact the metal as the weld is formed and alter the structure of the weld. According to the researchers, this process refines the metal’s crystal structure and decreases crystal size by nearly five times. Local media in Chelyabinsk initially reported on the research earlier this October.
Denser welds resist vibration and mechanical stress more effectively
Ultrasonic treatment also reduces the thickness of the brittle layers that develop between the metals by half. It helps eliminate air bubbles from the weld, resulting in denser and more durable joints. Testing revealed that the strength of the welded joint doubled using this new technique. The service life of the components increased by 90%, which is the same as the 1.9-fold improvement reported by SUSU. The researchers noted that these enhancements could improve resistance to prolonged vibration and mechanical stress.
These findings suggest potential advantages for parts subjected to continuous movement and heavy loads. According to SUSU, joints treated with this method can endure long-term vibrational stress without cracking. Such durability is particularly important in vehicles and aircraft, where components regularly face repeated stress during operation. The results were shared by the university and reported through TV BRICS.
Enabling lighter structures for automotive, aerospace, and construction sectors
The researchers indicated that this technology could find applications in the automotive, aerospace, and construction industries. Combining steel and aluminium allows manufacturers to reduce the weight of structures while maintaining their strength. The university pointed out that lightweight bodies for electric vehicles could particularly benefit from this method. In aviation, joining aluminium and steel parts can help decrease the overall mass of structures.
This project exemplifies ongoing scientific collaboration between Russian and Chinese researchers. Stronger joints between different metals could enable manufacturers to produce lighter, more durable components. The technique might support structures that combine the robustness of steel with aluminium’s low weight. Details regarding commercial implementation were not included in the reports.