MOSCOW, Russia / EuroWire.IO / – A novel ultrasonic welding approach, created by Russian and Chinese scientists, can increase the lifespan of metal parts by a factor of 1.9. According to South Ural State University, this technology also doubles the strength of welded joints. The Chelyabinsk-based university collaborated with colleagues from China to develop this process. The findings were reported by TV BRICS on October 19, with the study focusing on metals with varying properties.
Pairings like steel and aluminium exemplify the types of metals addressed. When these metals are welded together, brittle layers often form at the joint, which may lead to fractures under vibration or repeated stress. The new method mitigates this issue by improving the weld structure during spot welding. The university noted that the research was published in the journal Engineering Fracture Mechanics, though no individual researchers were named in the announcement.
During the process, ultrasonic waves of approximately 1,200 watts are applied while forming the spot weld. Rossiyskaya Gazeta reported that heating electrodes transmit these waves. This vibration disrupts the crystal structure of the metal, reducing crystal size by nearly five times, as stated by the university. Additionally, the brittle layers at the joint are cut in half in thickness, resulting in a more uniform weld that is less susceptible to cracking.
Denser welds better resist vibration stress
Applying ultrasound also expels air bubbles from the metal, creating a denser, stronger weld. Tests demonstrated that these joints are twice as durable, with the components’ service life increasing by 90%. The researchers emphasized that such parts can endure prolonged vibration and mechanical loads without developing cracks. This capability is particularly vital in vehicles, aircraft, and structures subjected to cyclic stress, where fatigue cracking at welds frequently causes failure.
The university’s statement described these improvements in relative terms and did not specify absolute strength measurements, alloy types, or the number of tested samples. Russia’s academic institutions have reported various materials research projects this year, including studies on coatings for titanium implants. South Ural State University has also pioneered a berberine-enriched cheese formulated to support immunity. The timeline for commercial application remains unspecified.
Potential uses in transportation and construction industries
The researchers see significant opportunities across automotive, aerospace, and construction sectors. For example, automakers could integrate a steel passenger cabin with aluminium doors, bonnet, and wings, forming a hybrid structure. Such a lighter design would enable electric vehicles to travel farther on a single charge. Aircraft manufacturers could produce lighter airliners capable of transporting more passengers or cargo, while also reducing fuel consumption per flight.
In construction, the technique could be applied to bridges and skyscrapers. The university stated that welded joints might surpass the strength of monolithic concrete. Other possible applications include attaching a steel column to an aluminium panel or welding a steel longeron to an aluminium subframe. This collaborative Russia-China project demonstrates that the method could lead to lighter, stronger structures in numerous industries.