MOSCOW, Russia / AsiaWire.IO / – Scientists from Russia and China have developed an ultrasonic welding technology that doubles the strength of metal joints, TV BRICS reported. The report cited South Ural State University, known as SUSU, whose researchers carried out the work with Chinese partners. The method also increases the service life of welded components by 1.9 times. It is designed to join metals with different properties, such as steel and aluminium, more reliably.
Merging steel and aluminium has long been a challenge for manufacturers. When these metals are welded, brittle intermetallic layers often form at the joint. These layers can serve as stress points, weakening the connection under load. The new technique aims to minimize these weak spots and reduce fracture risk at the joint. SUSU is based in the Russian city of Chelyabinsk.
During spot welding, the team applied ultrasonic waves with about 1,200 watts of power. The vibrations act directly on the metal as the weld forms, changing its structure. The researchers say the process refines the metal’s crystal structure and decreases crystal size by nearly five times. Local media in Chelyabinsk first reported on the research earlier in October.
Denser welds resist vibration and stress better
Ultrasonic treatment also halves the thickness of the brittle layers that develop between metals. It eliminates air bubbles from the weld, creating denser, stronger joints. Tests show that the strength of the joint doubled with this new process. The service life of components increased by 90%, which is a 1.9-fold improvement reported by SUSU. The researchers believe these enhancements could improve resistance to long-term vibration and mechanical stress.
These results suggest benefits for parts exposed to continuous movement and heavy loads. The university states that joints treated with this method can endure prolonged vibrational forces without cracking. Such durability is crucial in vehicles and aircraft, where parts face repeated stress during use. The findings were shared through TV BRICS and reported by the university.
Enabling lighter structures for vehicles, planes, and buildings
The researchers highlighted that the technology could be applied in automotive, aerospace, and construction sectors. Combining steel and aluminium allows manufacturers to create lighter yet strong structures. The university pointed out that this could be useful for electric vehicles. In aviation, joining aluminium and steel parts can help reduce the overall weight of structures.
This project exemplifies ongoing scientific collaboration between Russian and Chinese researchers. Stronger joints between different metals could help manufacturers build lighter, more durable components. The method has potential to combine steel’s strength with aluminium’s lightness. The reports did not specify any plans for commercial deployment.