MOSCOW, Russia / EuroWire.IO / – A novel ultrasonic welding approach, created through collaboration between Russian and Chinese researchers, can extend the lifespan of metal components by 1.9 times. According to South Ural State University, this technique also doubles the strength of welded connections. The university’s scientists, based in Chelyabinsk, developed the process alongside colleagues from China, with the results reported by TV BRICS on October 19. It is specifically designed for metals with differing properties.
Metals such as steel and aluminium serve as typical examples of such pairings. During welding, brittle layers tend to form at the interface, which can cause fractures under vibration or repetitive stress. The new method mitigates this issue by improving the weld’s internal structure during spot welding. The university stated that their research was published in Engineering Fracture Mechanics, though no individual researchers were named in the announcement.
This process employs ultrasonic waves of approximately 1,200 watts during the formation of the spot weld. Rossiyskaya Gazeta indicated that these waves are transmitted via heating electrodes. The vibrations disrupt the metal’s crystal lattice, leading to a reduction in crystal size by nearly five times, as reported by the university. Additionally, the brittle layers at the joint are cut in half in thickness. These structural modifications result in a more uniform weld that is less susceptible to cracking.
Denser welds resist vibration more effectively
Ultrasound also eliminates entrapped air bubbles, yielding a denser and more robust weld. Tests demonstrated that these joints are twice as strong, with the components’ service life increasing by 90%. The researchers noted that such parts can endure sustained vibration and mechanical loads longer without developing cracks. This improved durability is particularly relevant for vehicles, aircraft, and structural elements subjected to repeated stress. Fatigue cracks at welds are a common cause of component failure in these applications.
The university’s report quantified the improvements in relative terms but did not specify absolute strength values, alloy types, or the number of samples tested. This year, Russian universities have announced several materials research initiatives, including projects on coatings for titanium implants. South Ural State University has also developed a berberine-enriched cheese aimed at boosting immunity. No timeline for commercial application was provided by the university.
Potential uses in transportation and construction industries
The scientists envision applications across automotive, aerospace, and building sectors. For instance, car manufacturers could create a hybrid body by welding a steel passenger compartment with aluminium doors, bonnet, and wings. Such a lighter vehicle structure would enable electric cars to travel further on a single charge. Similarly, aircraft manufacturers could produce lighter airliners capable of carrying more passengers or cargo, with less fuel consumption per flight.
In construction, this method could be utilized in constructing bridges and skyscrapers. The university claimed that these welded joints could surpass the strength of monolithic concrete. Other examples include joining a steel longeron to an aluminium panel or attaching a steel component to an aluminium subframe. This research was conducted as a joint project between Russia and China. The university highlighted that this technique paves the way for lighter, stronger structures across multiple industries.