MOSCOW, Russia / AsiaWire.IO / – A novel ultrasonic welding process created by scientists from Russia and China significantly enhances the durability of metal joints and prolongs component lifespan, TV BRICS reported. The research was conducted by experts at South Ural State University in collaboration with Chinese scientists. The university noted that parts produced with this method last 1.9 times longer. The technique specifically targets joints between different metals, such as steel and aluminium.
Joining dissimilar metals often results in brittle layers where they meet. These intermetallic phases are hard and fragile, creating stress concentration zones. Such weaknesses can reduce a joint’s lifespan under load. The researchers designed their method to lower the risk of fractures in these layers. South Ural State University is based in Chelyabinsk, in Russia’s Ural region.
The process involves ultrasonic waves with around 1,200 watts of power during spot welding. These vibrations act on the metal during weld formation, altering its internal structure. The technique refines the metal’s crystal structure and reduces the crystal size by nearly five times. Chelyabinsk media reported on this research at the beginning of October, prior to the TV BRICS coverage.
Process reduces brittle layers and eliminates air pockets
The method cuts the thickness of brittle intermetallic layers in half. It also removes air bubbles from the weld, leading to denser, more resilient joints. Testing showed that joint strength doubled, and component lifespan increased by 90%. The researchers stated these improvements could boost resistance to long-term vibration and mechanical stress.
The university reported that joints made with this approach can withstand continuous vibrational loads over time without cracking. This is especially relevant for parts used in vehicles, aircraft, and buildings subjected to repeated stress. The findings were shared by the university and disseminated through TV BRICS. No timeline for commercial application was provided in either report.
Potential applications in automotive and aerospace sectors
Researchers indicated that the technology could be used in automotive, aerospace, and construction industries. Strong steel-aluminium joints enable engineers to create lighter structures without losing strength. The university cited lightweight electric vehicle bodies as an example. In aviation, connecting aluminium and steel parts can decrease aircraft weight.
This research strengthens scientific collaboration between Russia and China in materials and engineering. Improved joints between dissimilar metals could help manufacturers develop lighter, more durable products. The method combines the strength of steel with aluminium’s lightness within a single structure. The researchers believe it allows the production of lighter, stronger frameworks.