MOSCOW, Russia / AsiaWire.IO / – A novel ultrasonic welding method developed by Russian and Chinese researchers has been reported by TV BRICS, capable of doubling the strength of metal connections. The innovation, highlighted by South Ural State University, known as SUSU, was carried out with Chinese collaborators. The technique not only boosts joint durability but also extends the service life of welded parts by 1.9 times. It is especially designed to facilitate more reliable bonding between metals with differing properties, such as steel and aluminium.
Creating strong welds between steel and aluminium has historically been difficult, primarily due to the formation of brittle intermetallic layers that can develop at the joint. These layers often serve as stress points, decreasing the overall resilience of the connection under load. The new ultrasonic approach aims to minimize these weak spots and reduce the likelihood of fractures. SUSU, located in Chelyabinsk, Russia, led the research.
During spot welding, the team employed ultrasonic waves around 1,200 watts in power. The vibrations directly impact the metal as the weld forms, altering the weld’s internal structure. The researchers noted that this process refines the metal’s crystal structure, decreasing crystal size by nearly five times. Chelyabinsk local media first reported on the research in early October.
Denser welds resist vibration and mechanical stress better
This ultrasonic treatment also reduces the thickness of the brittle intermetallic layers by 50%, while effectively eliminating air bubbles within the weld. The result is a denser, more durable joint. Testing revealed that the strength of the welded connection doubled with this new process, and the lifespan of components increased by 90%, matching the 1.9-fold improvement reported by SUSU. The researchers believe these advancements could enhance resistance to continuous vibration and mechanical load.
These findings suggest significant benefits for parts exposed to constant motion and heavy stress. According to the university, joints treated with this method can endure long-term vibrational forces without cracking, which is critical for applications in vehicles and aircraft where components experience repeated stress during operation. The results were shared via TV BRICS and university reports.
Enabling lighter construction materials for automotive and aerospace sectors
The scientists indicated that this technology could find applications within automotive, aerospace, and construction industries. Combining steel with aluminium allows manufacturers to produce lighter yet sturdy structures. The university emphasized potential use in electric vehicles, where lightweight bodies are increasingly important. In aviation, integrating aluminium and steel components can significantly reduce overall weight.
This initiative exemplifies ongoing collaborative efforts between Russian and Chinese scientists. Stronger joints between dissimilar metals could enable the manufacturing of lighter, more durable parts. The technique supports the creation of hybrid structures that combine steel’s strength with aluminium’s low weight. Specific details about commercial implementation were not included in the reports.