MOSCOW, Russia / AsiaWire.IO / – A collaborative effort between scientists from Russia and China has led to the creation of an ultrasonic welding technique that effectively doubles the tensile strength of metal joints, according to TV BRICS. The development was carried out by researchers from South Ural State University, also known as SUSU, in partnership with Chinese experts. This method not only enhances the mechanical robustness but also extends the operational lifespan of welded parts by 1.9 times. It is specifically designed to improve the reliability of bonding metals with differing characteristics, such as steel and aluminium.
For a long time, welding steel to aluminium has presented significant challenges for industry. The formation of brittle intermetallic layers at the joint can occur, which serve as stress concentration points and compromise the joint’s durability under load. The innovative technique aims to minimize these weak spots, thereby reducing the likelihood of fractures. SUSU is located in Chelyabinsk, Russia.
During spot welding, the team applied ultrasonic vibrations with an approximate power of 1,200 watts. These vibrations directly influence the metal as the weld is formed, inducing structural changes within the weld zone. The researchers observed that this process refines the metal’s crystal structure, decreasing the crystal size by nearly five times. Local media in Chelyabinsk first reported on these findings earlier this October.
Denser welds resist vibration and mechanical stress better
The ultrasonic process also reduces the thickness of the brittle intermetallic layers by half and effectively eliminates air bubbles within the weld, resulting in joints that are both denser and more resilient. Testing revealed that the strength of welded connections doubled when utilizing this approach. Additionally, the lifespan of the components increased by 90%, matching the 1.9-fold enhancement reported by SUSU. The researchers indicated that these improvements could significantly enhance resistance to prolonged vibration and mechanical forces.
These promising results suggest substantial benefits for parts subjected to continuous movement and heavy loads. According to the university, joints treated with this ultrasonic method can endure long-term vibrational stresses without cracking. Such durability is crucial in the automotive and aerospace sectors, where components are regularly exposed to repeated operational stresses. The findings were disseminated by the university and featured on TV BRICS.
Lighter construction materials for transportation and infrastructure
The research team noted that the ultrasonic welding technology has potential applications across the automotive, aerospace, and construction industries. The combination of steel and aluminium allows for the creation of lighter yet strong structures. The university emphasized the potential use of this technique for manufacturing electric vehicle bodies. In aviation, joining aluminium and steel components can help reduce the overall weight of aircraft structures.
This initiative underscores ongoing scientific collaboration between Russian and Chinese researchers. Enhanced bonding of dissimilar metals could lead to the production of lighter, more durable components. The approach supports the development of structures that leverage the strength of steel with the low weight of aluminium. Details regarding commercial implementation were not included in the reports.