MOSCOW, Russia / EuroWire.IO / – South Ural State University has announced a novel ultrasonic welding method developed jointly by Russian and Chinese scientists, capable of extending the lifespan of metal components by 1.9 times. This innovative process also results in a doubling of the strength of welded joints, according to the university. The method was created through collaboration between the Chelyabinsk-based university and Chinese colleagues. The findings were reported by TV BRICS on October 19, citing the university. The technique is tailored for metals with different characteristics.
A typical example of such a metal pairing is steel and aluminium. When these metals are welded, brittle layers often develop at the joint, which can cause fractures under vibration and repetitive stress. The new approach mitigates this issue by improving the weld structure during spot welding. The university indicated that the research was published in the journal Engineering Fracture Mechanics. No specific researchers were named in the publication.
During the welding process, ultrasonic waves with approximately 1,200 watts of power are applied as the spot weld forms. According to Rossiyskaya Gazeta, these waves are transmitted through heating electrodes. The vibration disrupts the metal’s crystal lattice, reducing the crystal size within the weld by nearly five times, as per the university. Consequently, the brittle layers at the joint become half as thick. These modifications produce a more uniform weld that is less susceptible to cracking.
Denser welds resist vibration damage
The ultrasonic treatment also expels trapped air bubbles from the metal, resulting in a denser, stronger weld. Testing revealed that the welded joints are twice as durable, with the service life of the components increasing by 90%. The scientists explained that these parts can endure prolonged vibration and mechanical stress without developing cracks. Such durability is critical for use in vehicles, aircraft, and structures subjected to repeated loads, where fatigue cracking at welds often leads to failure.
The university’s announcement emphasized the relative improvements but did not specify absolute strength figures, alloy types, or the number of samples tested. This year, Russian academic institutions have reported multiple materials research projects, including developments in coatings for titanium implants. South Ural State University also created a berberine-enriched cheese to support immunity. The university did not specify when the method might see industrial application.
Potential uses in transportation and construction industries
The researchers see promising applications across automotive, aerospace, and construction fields. Automakers could combine steel passenger cabins with aluminium doors, bonnets, and wings into a single hybrid structure. A lighter vehicle would enable electric cars to travel farther on a single charge. Aircraft manufacturers could produce lighter airliners capable of carrying more passengers or cargo, which would also reduce fuel consumption per flight.
In the construction sector, this welding method could be employed for bridges and skyscrapers. The university claimed that the welds produced through this technique could outperform monolithic concrete in strength. Additional examples include joining a steel column to an aluminium panel or welding a steel longeron to an aluminium subframe. The research was conducted as a joint project between Russia and China. The university highlighted that this approach paves the way for lighter, stronger structures across multiple industries.