MOSCOW, Russia / EuroWire.IO / – A novel ultrasonic welding approach created by scientists from Russia and China can extend the lifespan of metal components by 1.9 times. The method also doubles the robustness of welded connections, according to South Ural State University. Researchers from the Chelyabinsk-based institution collaborated with colleagues from China to develop this process. The findings were reported by TV BRICS on October 19, citing the university. This technique is suitable for metals with differing properties.
Common examples include steel and aluminium. When these metals are welded together, brittle layers often form at the joint. Such layers can cause fractures, especially under vibration and repeated mechanical stress. The new method mitigates this risk by improving the weld’s internal structure during spot welding. The university stated that the research was published in the journal Engineering Fracture Mechanics. The announcement did not specify individual researchers involved.
The process involves applying ultrasonic waves with approximately 1,200 watts of power during the formation of the spot weld. According to Rossiyskaya Gazeta, these waves are transmitted through heating electrodes. The vibrations disrupt the crystal structure of the metals. As a result, the crystal size in the weld reduces by nearly five times. The brittle layers at the joint become half as thick. These structural modifications produce a more uniform weld that is less susceptible to cracking.
Denser welds offer improved resistance to vibration
Ultrasound treatment also eliminates air bubbles within the metal, resulting in a denser, stronger weld. Testing showed that the joints were twice as durable. The service life of these parts increased by 90%. The researchers emphasized that components could withstand continuous vibration and mechanical loads longer without developing cracks. Such durability is critical for vehicles, aircraft, and infrastructure exposed to repetitive stress. Fatigue cracking at weld points is a frequent cause of component failure.
The university’s report expressed the improvements in relative terms. It did not provide specific absolute strength values, alloy grades, or the number of samples tested. Russian academic institutions have announced several materials research initiatives this year, including developments on coatings for titanium implants. South Ural State University has also created a berberine-enriched cheese aimed at supporting immunity. No timeline for industrial application was provided by the university.
Potential uses in automotive, aerospace, and construction industries
The scientists foresee applications across various sectors such as automotive, aerospace, and construction. For example, car manufacturers could connect a steel passenger cell with aluminium doors, bonnet, and wings to create a hybrid structure. Lighter vehicles would enable electric cars to travel longer distances per charge. In aerospace, lighter airliners could be designed to carry more passengers or cargo, reducing fuel consumption per flight.
In construction, this welding technique might be applied to bridges and skyscrapers. The university indicated that welded joints could surpass the strength of monolithic concrete. Other examples include attaching a steel column to an aluminium panel or welding a steel longeron to an aluminium subframe. This project was a joint effort between Russia and China. The university highlighted that the method paves the way for creating structures that are both lighter and more durable across multiple industries.