MOSCOW, Russia / AsiaWire.IO / – According to TV BRICS, a novel ultrasonic welding technique created by scientists from Russia and China significantly boosts the durability of metal joints and prolongs the lifespan of components. This innovation was developed by researchers at South Ural State University in collaboration with Chinese scientists. The university reports that parts produced using this method last 1.9 times longer. The approach specifically targets joints between dissimilar metals, such as steel and aluminium.
Welding different metals often results in the formation of brittle intermetallic layers at the interface. These layers are typically hard yet fragile, acting as stress concentration zones that can weaken the joint. Such weaknesses can lead to premature failure under load. The scientists aimed to minimize fracture risks associated with these layers through their new technique. Located in Chelyabinsk, Russia’s Ural region, the university conducted the research.
During spot welding, ultrasonic waves with an approximate power of 1,200 watts are applied. These vibrations influence the metal as the weld forms, altering its internal structure by refining the crystal formation and reducing crystal size by nearly five times. Early reports from Chelyabinsk media, published at the beginning of October, covered the research prior to the TV BRICS feature.
Refinement reduces brittle layers and eliminates air pockets
This process effectively halves the thickness of the brittle intermetallic layers at the joint and also removes entrapped air bubbles, resulting in more compact and resilient welds. Testing revealed that joint strength doubled, and the lifespan of the components increased by 90%. The research team indicated that these improvements could enhance resistance to long-term vibration and mechanical stress.
The university states that joints produced with this method can withstand continuous vibrational forces over extended periods without cracking. Such durability is essential for parts used in vehicles, aircraft, and structures subjected to repetitive stress. The findings were shared by the university and disseminated through TV BRICS, though no specific timeline for commercial adoption was provided.
Potential applications in automotive and aerospace sectors
Researchers believe this technology could be valuable in the automotive, aerospace, and construction industries. Creating robust steel-aluminium joints enables engineers to develop lighter structures without compromising strength. The university highlighted lightweight body panels for electric vehicles as an example. In aviation, connecting aluminium and steel components can contribute to reducing aircraft weight.
This research enhances the scientific collaboration between Russia and China in the fields of materials and engineering. Improved joints between dissimilar metals could lead to the production of lighter, more durable products. The method combines steel’s strength with aluminium’s low weight in integrated structures, allowing for the creation of lighter, yet stronger, designs, according to the researchers.