MOSCOW, Russia / AsiaWire.IO / – According to TV BRICS, the South Ural State University, known as SUSU, has teamed up with Chinese partners to develop an ultrasonic welding method that enhances the durability of metal joints. This innovation not only doubles the strength of welded connections but also extends the service life of the components by 1.9 times. The technique is especially effective for joining metals with differing properties, such as steel and aluminium, with greater reliability.
Creating secure bonds between steel and aluminium has traditionally been difficult for manufacturers. Welding these metals often results in brittle intermetallic layers that can form at the joint, acting as stress points and compromising the connection’s longevity under load. The new ultrasonic welding approach aims to mitigate these weak spots, reducing the likelihood of fractures. SUSU is located in Chelyabinsk, Russia.
During spot welding, the team introduced ultrasonic vibrations with an approximate power of 1,200 watts. These vibrations directly impact the metal as the weld forms, altering its internal structure. Researchers note that this process refines the metal’s crystal structure, decreasing crystal size by nearly five times. Earlier in October, local media in Chelyabinsk first reported on this research.
Denser, vibration-resistant welds
The ultrasonic process also reduces the thickness of the brittle intermetallic layers by half, while eliminating air bubbles from the weld to produce denser, more resilient joints. Testing has demonstrated that the strength of the welds doubled when using this method. The lifespan of the components saw a 90% increase, equivalent to the 1.9-fold enhancement reported by SUSU. The scientists believe these improvements could increase resistance to prolonged vibration and mechanical stress.
These findings suggest significant benefits for parts subjected to continuous movement and heavy loads. According to SUSU, joints treated with this ultrasonic technique can endure long-term vibrational stresses without cracking. Such durability is crucial in sectors like automotive and aerospace industries, where repeated stress during operation is common. The results were shared via TV BRICS and reported by the university.
Enhanced lightweight designs for vehicles, aircraft, and structures
The scientists indicated that this technology could find applications across automotive, aerospace, and construction sectors. Merging steel with aluminium enables manufacturers to develop lighter structures without sacrificing strength. The university pointed to the potential use in electric vehicles as an example. In aviation, combining aluminium and steel components can contribute to reducing overall weight.
This project exemplifies ongoing scientific collaboration between Russian and Chinese researchers. Stronger bonds between different metals could allow for the production of lighter yet more durable parts. The method may facilitate the development of structures that leverage steel’s strength alongside aluminium’s lightness. Details regarding commercial implementation were not included in the reports.