MOSCOW, Russia / AsiaWire.IO / – In Chelyabinsk, Russia, during October, scientists from Russia and China announced a breakthrough in welding technology. They have developed an ultrasonic welding method that enhances the strength of metal joints by two times, according to TV BRICS. The innovation, detailed by South Ural State University, known as SUSU, was achieved through collaboration with Chinese partners. Additionally, this approach extends the lifespan of welded parts by 1.9 times and is particularly effective for joining metals with contrasting properties, such as steel and aluminium, with greater reliability.
For years, connecting steel and aluminium has been a persistent challenge for manufacturers. The welding process often results in the formation of brittle intermetallic layers at the joint, which can act as stress points and weaken the connection under load. The new ultrasonic welding technique aims to reduce these vulnerabilities, lowering fracture risks 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 influence the metal as the weld forms, altering the weld’s internal structure. The researchers report that this process refines the crystal structure of the metal, decreasing crystal size nearly fivefold. Local media in Chelyabinsk first covered this research in early October.
Denser welds resist vibration and mechanical stress better
The ultrasonic process also reduces the thickness of the brittle intermetallic layers by half, removing air bubbles from the weld to produce more compact and durable joints. Testing revealed that the strength of the joint doubled using this method. The lifespan of welded components increased by 90%, matching the 1.9 times improvement reported by SUSU. The researchers suggest these enhancements could lead to increased resistance to sustained vibration and mechanical forces.
These findings imply significant advantages for parts subjected to continuous movement and heavy loads. According to SUSU, joints treated with this ultrasonic technique can endure long-term vibrational stress without cracking. Such durability is crucial for components used in vehicles and aircraft, where repeated stress is common. The results were shared through TV BRICS and documented by the university.
Enabling lighter designs for automotive, aerospace, and construction sectors
The scientists indicated that this technology could be applicable across the automotive, aerospace, and construction industries. Combining steel and aluminium allows manufacturers to produce lighter yet robust structures. The university pointed out that lightweight bodies for electric vehicles could benefit from this method. In aviation, joining aluminium and steel components may help reduce the overall weight of aircraft structures.
This project exemplifies ongoing scientific collaboration between Russian and Chinese researchers. Stronger bonds between dissimilar metals could facilitate the creation of lighter, more durable components. The technique might support the development of structures that combine steel’s strength with aluminium’s lightness. Details regarding commercial implementation were not included in the reports.