MOSCOW, Russia / AsiaWire.IO / – A novel ultrasonic welding process created through collaboration between Russian and Chinese researchers significantly enhances the durability of metal joints and prolongs component lifespan, according to TV BRICS. The development was led by scientists at South Ural State University in partnership with Chinese experts. The university highlighted that parts fabricated using this method last 1.9 times longer. This technique specifically targets joints between different metals, such as steel and aluminium.
Combining dissimilar metals through welding often results in brittle intermetallic layers that form at the interface. These layers tend to be hard yet fragile, serving as stress concentration zones that can compromise joint integrity. Such weaknesses tend to reduce the lifespan of a joint under load. The scientists aimed to address this issue by designing a method to mitigate fracture risks associated with these layers. The university is based in Chelyabinsk, situated in Russia’s Ural region.
During spot welding, ultrasonic vibrations with a power of roughly 1,200 watts are applied. These vibrations influence the metal as the weld forms, modifying its internal structure. This process refines the metal’s crystal configuration and reduces the crystal size by nearly five times. Reports from Chelyabinsk media in early October, prior to the TV BRICS article, covered the research findings.
Process reduces brittle layers and expels trapped air
The ultrasonic technique halves the thickness of the brittle intermetallic layers at the joint and also eliminates air bubbles within the weld. This results in more compact, robust connections. Tests demonstrated that joint strength doubled, and the lifespan of the components increased by 90%. The scientists noted that these improvements could enhance resistance to long-term vibration and mechanical stress.
The university states that joints created with this method can withstand continuous vibrational forces over extended periods without cracking. This resilience is particularly relevant for parts used in vehicles, aircraft, and buildings subjected to repeated stress cycles. The findings were shared by the university and disseminated through TV BRICS. Neither report provided a schedule for commercial deployment.
Potential applications in automotive and aerospace sectors
The scientists suggested that the technique could be adopted by the automotive, aerospace, and construction industries. Strong steel-aluminium joints enable engineers to develop lighter structures without compromising strength. The university cited lightweight bodies for electric vehicles as an example. In the field of aviation, connecting aluminium and steel components can significantly reduce aircraft mass.
This research further signifies the scientific partnership between Russia and China in the areas of materials science and engineering. Improved bonding between dissimilar metals could assist manufacturers in producing lighter yet durable products. The approach leverages steel’s strength with aluminium’s low weight to create integrated, lighter structures. The scientists emphasized that their method supports manufacturing lighter, more resilient assemblies.