MOSCOW, Russia / EuroWire.IO / – A novel ultrasonic welding approach developed through collaboration between Russian and Chinese scientists has been shown to extend the lifespan of metal parts by 1.9 times. According to South Ural State University, this technology also doubles the strength of welded joints. The process was created jointly by researchers at the Chelyabinsk-based university and their colleagues from China. The findings were reported by TV BRICS on October 19, citing the university. The technique is tailored for metals with differing properties.
Commonly, steel and aluminium are paired in such applications. When these metals are welded, brittle layers tend to form at the interface, which can cause fractures under vibration or repeated mechanical stress. The new method mitigates this issue by enhancing the weld’s structural integrity during spot welding. The university announced that the research was published in the journal Engineering Fracture Mechanics. However, it did not specify the individual researchers involved.
During the process, ultrasonic waves with an approximate power of 1,200 watts are applied while the spot weld is formed. Rossiyskaya Gazeta reported that heating electrodes transmit the vibrations. These vibrations disrupt the metal’s crystal structure, resulting in a crystal size reduction of nearly five times in the weld. The brittle layers at the joint become half as thick, leading to a more uniform weld that is less vulnerable to cracking, the university stated.
More compact welds resist vibration better
Ultrasound also eliminates entrapped air bubbles within the metal, creating a denser weld. Testing revealed that the welded joints achieved twice the strength of traditional methods. The components’ service life increased by 90%. The researchers explained that these parts could endure prolonged exposure to constant vibration and mechanical loads without developing cracks. Such durability is particularly significant for vehicles, aircraft, and construction structures that experience repeated stress cycles. Fatigue cracks at welds are a frequent failure cause in these applications.
The university’s report highlighted the relative improvements but did not include specific data such as absolute strength measurements, alloy grades, or the number of samples tested. Earlier this year, Russian institutions announced several materials research initiatives, including coatings for titanium implants. South Ural State University has also developed a berberine-enriched cheese aimed at supporting immunity. The university did not specify when the technology might be adopted industrially.
Potential uses in transportation and construction
The research team envisions applications across the automotive, aerospace, and building industries. For example, automakers could integrate a steel passenger cell with aluminium doors, bonnet, and wings into a unified hybrid structure. Such a lightweight design could enable electric vehicles to travel further on a single charge. Similarly, aircraft manufacturers could produce lighter airliners capable of transporting more passengers or cargo while consuming less fuel per flight.
In construction, the method could be applied to bridges and skyscrapers. The university noted that welded joints might surpass the strength of monolithic concrete. Other potential uses include joining a steel longeron to an aluminium panel or attaching a steel structural element to an aluminium subframe. This research was conducted as a joint project between Russia and China. The university emphasized that this method paves the way for creating lighter, stronger structures across diverse sectors.