MOSCOW, Russia / AsiaWire.IO / – A groundbreaking ultrasonic welding process created by scientists from Russia and China has been shown to double the strength of metal connections and increase the lifespan of components, as reported by TV BRICS. This advancement was achieved by researchers at South Ural State University in collaboration with Chinese experts. The university highlighted that parts manufactured with this method last 1.9 times longer. The approach specifically targets joints between different metals, such as steel and aluminium.
Welding metals with contrasting properties often results in the formation of brittle intermetallic layers at the interface. These layers are hard, fragile, and tend to concentrate stress, which can lead to premature failure under load. To address this issue, the scientists developed a technique to minimize the risk of fractures caused by such layers. South Ural State University, situated in Chelyabinsk in Russia’s Ural region, announced the findings.
The method involves applying ultrasonic waves of approximately 1,200 watts power during spot welding. These vibrations influence the metal while the weld is being created, altering its internal structure. The process significantly refines the metal’s crystal structure, reducing crystal size by nearly five times. Reports from Chelyabinsk media in early October, prior to the TV BRICS coverage, detailed the research.
Refinement reduces brittle layers and eliminates trapped air bubbles
This technique cuts the thickness of brittle intermetallic layers in half at the joint. Additionally, it eradicates air bubbles within the weld, resulting in stronger, more compact connections. Testing revealed that joint strength was doubled, and the service life of the assembled parts increased by 90%. The team noted that these improvements could enhance resistance to sustained vibration and mechanical stress.
The university explained that joints created through this process can withstand continuous vibrational forces over extended periods without cracking. Such durability is crucial for components used in vehicles, aircraft, and structures subjected to repetitive stress. The results were shared by the university and disseminated through TV BRICS, with no specific timeline given for commercial deployment.
Key applications likely in automotive and aerospace fields
The researchers indicated that this technology could be utilized in the automotive, aerospace, and construction industries. Creating robust steel-aluminium joints enables engineers to develop lighter structures without compromising strength. The university pointed to lightweight electric vehicle bodies as an example. In aviation, connecting aluminium and steel components can help reduce aircraft weight, improving efficiency.
This research enhances scientific collaboration between Russia and China in the fields of materials and engineering. Improved bonding between dissimilar metals can lead to the production of lighter, more durable products. The method combines steel’s strength with aluminium’s lightness within a single framework. The researchers concluded that their approach allows for the manufacturing of structures that are both lighter and stronger.