MOSCOW, Russia / AsiaWire.IO / – Researchers from South Ural State University, known as SUSU, in collaboration with Chinese partners, have created an ultrasonic welding process that enhances the strength of metal joints by two times, as reported by TV BRICS. This innovative method also extends the lifespan of welded parts by 1.9 times, offering a more reliable way to join metals with differing properties, such as steel and aluminium.
For a long time, the welding of steel to aluminium has been challenging due to the formation of brittle intermetallic layers at the joint. These hard layers can act as stress points, compromising the joint’s durability under load. The new ultrasonic technique aims to minimize these weak spots and significantly reduce the risk of fractures. SUSU is based in Chelyabinsk, Russia.
The process involves applying ultrasonic waves with a power of approximately 1,200 watts during spot welding. The vibrations act directly on the metals as the joint is formed, altering the weld’s internal structure. Researchers noted that this process refines the metal’s crystal structure, decreasing the crystal size by nearly five times. The initial reports on this research appeared earlier in October through local media in Chelyabinsk.
Denser welds improve resilience against vibration and stress
The ultrasonic treatment also reduces the thickness of the brittle intermetallic layers by 50%. It effectively eliminates air bubbles within the weld, resulting in joints that are denser and more resistant to wear. Testing indicated that the strength of the joint doubled using this method, and the lifespan of components increased by 90%, aligning with the 1.9 times improvement reported by SUSU. The team emphasized that these enhancements could increase resistance to ongoing vibration and mechanical loads.
These findings suggest significant benefits for parts subjected to continuous movement and heavy stress. According to SUSU, joints processed with this technique can endure prolonged vibrational forces without cracking, which is critical for applications in vehicles and aircraft where repeated stress occurs during operation. The research was shared through TV BRICS and reported by the university.
Potential for lighter automotive, aerospace, and construction structures
The scientists indicated that this ultrasonic welding technology could find applications across automotive, aerospace, and construction sectors. Combining steel with aluminium enables manufacturers to reduce the weight of structures while maintaining their strength. The university specifically pointed to the possibility of creating lightweight bodies for electric vehicles. In aviation, welding aluminium and steel components can help decrease overall structural mass.
This project exemplifies ongoing international scientific collaboration between Russia and China. Stronger bonds between dissimilar metals could allow manufacturers to produce components that are both lighter and more durable. The technique offers a way to combine the strength of steel with aluminium’s low weight, although specific details regarding commercial implementation have not been disclosed in the reports.