MOSCOW, Russia / EuroWire.IO / – A novel ultrasonic welding approach created through collaboration between Russian and Chinese scientists has demonstrated the potential to extend the lifespan of metal parts by 1.9 times. According to South Ural State University, this method also enhances the tensile strength of welded joints, effectively doubling it. The development was carried out by researchers at the Chelyabinsk-based institution alongside colleagues from China. On October 19, TV BRICS shared these insights, citing the university as the source. This technique is tailored to accommodate metals with differing characteristics.
An example of such metal pairings includes steel and aluminium. When these materials are welded, brittle layers often develop at the interface, which can result in fractures under vibration or repeated mechanical stress. The innovative method mitigates this issue by improving the weld’s microstructure during spot welding. The university noted that the research findings were published in the journal Engineering Fracture Mechanics, although no individual researchers were named in the announcement.
The process involves applying ultrasonic waves with approximately 1,200 watts of power during the formation of the spot weld. Rossiyskaya Gazeta reported that these waves are transmitted through heating electrodes, causing vibrations that disrupt the crystal structure of the metal. According to the university, the crystal size within the weld diminishes nearly fivefold, while the thickness of brittle layers at the joint is reduced by half. These structural modifications result in a more uniform weld that is less susceptible to cracking.
Denser welds endure vibration better
The ultrasonic treatment also serves to eliminate air bubbles from the metal, producing a more compact weld. Tests demonstrated that these joints were twice as strong as traditional welds. The service life of the parts increased by 90%. The researchers emphasize that such components can withstand prolonged exposure to vibration and mechanical loads without developing cracks. This performance characteristic is crucial for vehicles, aircraft, and infrastructure subjected to repetitive stress. Fatigue cracking at welds remains a common cause of component failure.
The university highlighted these improvements in relative terms, without providing specific strength metrics, alloy types, or details about the number of samples tested. This year, Russian academic institutions have reported various materials research projects, including work on coatings for titanium implants. South Ural State University has also pioneered a berberine-enriched cheese aimed at boosting immunity. No timeline has been provided for commercial adoption of the new technique.
Potential impacts on transportation and structural engineering
The research team envisions applications across automotive, aerospace, and construction sectors. Automakers could create hybrid bodies by joining steel passenger compartments with aluminium doors, hoods, and wings. Such lighter structures could extend the driving range of electric vehicles. Similarly, aircraft manufacturers could develop lighter airliners capable of carrying more passengers or cargo, leading to reduced fuel consumption per flight.
In construction, the ultrasonic welding technique might be used to strengthen joints in bridges and skyscrapers. The university claims that welded connections could outperform monolithic concrete in strength. Additional applications include welding steel columns to aluminium panels or attaching steel longerons to aluminium subframes. This research was a joint project between Russia and China. The university states that this method paves the way for producing lighter yet more durable structures across multiple industries.