MOSCOW, Russia / AsiaWire.IO / – According to TV BRICS, a novel ultrasonic welding process created by scientists from Russia and China significantly increases the robustness of metal connections and prolongs component lifespan. The research was conducted by experts at South Ural State University in collaboration with Chinese scientists. The university indicated that parts produced through this method last approximately 1.9 times longer. This technique specifically targets joints between different metals, such as steel and aluminium.
Welding dissimilar metals often results in brittle intermetallic layers at the joint interface, which are prone to stress concentration and can compromise the joint’s durability under load. To address this issue, the researchers developed a method aimed at minimizing fracture risks associated with these fragile layers. The university, situated in Chelyabinsk within Russia’s Ural region, reports that their approach reduces the formation of such brittle zones.
During spot welding, ultrasonic waves with a power of roughly 1,200 watts are applied, causing vibrations that influence the metal during the welding process. These vibrations alter the internal structure of the material, refining the crystal structure and reducing the crystal size by nearly five times, which results in stronger, more reliable welds. Chelyabinsk media covered this research at the beginning of October, prior to the TV BRICS coverage.
Process reduces brittle layers and eliminates trapped air
The innovative technique cuts the thickness of brittle intermetallic layers in half and also effectively removes air bubbles from the weld, leading to denser and more durable connections. Testing demonstrated that joint strength doubled and the service life of the components increased by 90%, with researchers noting that these improvements could enhance resistance to sustained vibration and mechanical stress.
The university emphasizes that joints created using this method can withstand continuous vibrational forces over extended periods without cracking, making it particularly suitable for use in vehicles, aircraft, and construction elements that are subject to repeated loading. These findings were shared by the university and disseminated through TV BRICS, but no specific timeline for commercial application was provided in either report.
Potential applications in automotive and aerospace sectors
The researchers highlighted that this technology could be utilized within the automotive, aerospace, and construction industries. Producing strong steel-aluminium joints enables engineers to create lighter structures without compromising strength. For instance, the university pointed to lightweight vehicle bodies for electric vehicles as a potential application. In aviation, connecting aluminium and steel components can significantly decrease the weight of aircraft frameworks.
This research exemplifies the ongoing scientific collaboration between Russia and China in materials science and engineering. Improved dissimilar metal joints could facilitate the development of products that are both lighter and more durable. The method combines steel’s strength with aluminium’s low weight within a single structure, enabling the production of lighter, more resilient assemblies, according to the researchers.