MOSCOW, Russia / AsiaWire.IO / – A new ultrasonic welding method developed by Russian and Chinese scientists doubles the strength of metal joints and extends component life, TV BRICS reported. The work was carried out by researchers at South Ural State University in cooperation with scientists from China. The university said parts made with the technique last 1.9 times longer. The method targets joints between dissimilar metals, such as steel and aluminium.
Welding metals with different properties often creates brittle layers where they meet. These intermetallic phases are hard and fragile, and they can become zones of stress concentration. That weakness can shorten the life of a joint when it is placed under load. The researchers designed their approach to reduce the risk of fractures caused by these layers. The university is located in Chelyabinsk, in Russia’s Ural region.
The technique applies ultrasonic waves with a power of about 1,200 watts during spot welding. The vibrations act on the metal while the weld is forming, changing its internal structure. This refines the crystal structure of the metal and cuts crystal size by nearly five times. Chelyabinsk media reported on the research at the start of October, before the TV BRICS report.
Treatment halves brittle layers and removes air bubbles
The process halves the thickness of the brittle intermetallic layers at the joint. It also removes air bubbles from the weld, resulting in denser and more durable connections. In tests, joint strength doubled and the service life of components rose by 90%. The researchers said the gains could improve resistance to prolonged vibration and mechanical stress.
According to the university, joints produced with the method can endure constant vibrational loads over long periods without cracking. That performance is relevant for components in vehicles, aircraft and buildings that face repeated stress. The results were reported by the university and distributed through TV BRICS. Neither report set out a timeline for commercial production.
Automotive and aerospace industries seen as key users
The technology could find use in the automotive, aerospace and construction sectors, the researchers said. Strong steel-aluminium joints allow engineers to design lighter structures without sacrificing strength. The university cited lightweight bodies for electric vehicles as an example. In aviation, connecting aluminium and steel parts can reduce the mass of aircraft structures.
The research adds to scientific cooperation between Russia and China in materials and engineering. Better joints between dissimilar metals could help manufacturers build lighter and longer-lasting products. The approach combines the strength of steel with the low weight of aluminium in a single structure. The researchers said the method enables the production of lighter, stronger structures.