MOSCOW, Russia / AsiaWire.IO / – Researchers from Russia and China have created an ultrasonic welding approach that enhances the strength of metal connections by two times, as reported by TV BRICS. The article referenced South Ural State University, known as SUSU, which collaborated with Chinese partners on this project. This method also extends the lifespan of welded parts by 1.9 times. Its purpose is to more reliably join metals with differing characteristics, such as steel and aluminium.
Combining steel and aluminium has traditionally been a significant challenge for industry. During welding, fragile intermetallic layers can develop at the joint, potentially acting as stress concentration points and weakening the overall durability of the connection under load. The innovative technique seeks to mitigate these vulnerabilities and decrease the likelihood of fractures. SUSU, situated in Chelyabinsk, Russia, spearheaded the research.
During spot welding, the team applied ultrasonic vibrations with a power level around 1,200 watts. These vibrations directly affect the metal as the weld forms, altering its internal structure. According to the scientists, this process refines the metal’s crystal structure and diminishes the crystal size by nearly five times. The local media in Chelyabinsk initially reported on this research earlier in October.
Denser welds resist vibration and mechanical stress better
This ultrasonic process also reduces the thickness of the brittle layers that typically develop between dissimilar metals by half. It eliminates air pockets within the weld, resulting in joints that are both denser and more resilient. Testing revealed that the strength of the joints doubled using this technique. The lifespan of the components also increased by 90%, which is equivalent to the 1.9 times longer service life reported by SUSU. The researchers indicated that these enhancements could improve resistance to sustained vibration and mechanical loads.
These outcomes suggest potential benefits for parts subjected to continuous movement and heavy stress. As per the university, joints processed with this method can endure prolonged vibrational forces without cracking. Such durability is crucial for applications in vehicles and aircraft, where components experience repeated stress during operation. The findings were announced by the university and disseminated through TV BRICS.
Creating lighter structures for automotive, aerospace, and construction sectors
The scientists noted that this technology could be applied within the automotive, aerospace, and construction industries. Merging steel and aluminium allows manufacturers to reduce the weight of structures while maintaining strength. The university pointed out that lightweight bodies for electric vehicles could benefit from this method. In aviation, joining aluminium and steel components could help lower the overall mass of structures.
This project exemplifies ongoing scientific collaboration between Russian and Chinese researchers. Stronger bonds between different metals could enable the production of lighter, more durable parts. The technique has the potential to facilitate the development of structures combining steel’s robustness with aluminium’s low weight. Specific details regarding commercial implementation were not included in the reports.