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.
For a long time, welding steel to aluminium has been a significant challenge for manufacturers. When these metals are joined, brittle intermetallic layers can form at the interface, creating stress concentration zones that weaken the connection under load. The new ultrasonic welding approach seeks to mitigate these weak points and reduce fracture risks. SUSU is located in the Russian city of Chelyabinsk.
During spot welding, the team applied ultrasonic waves with approximately 1,200 watts of power. These vibrations act directly on the metals, altering the weld’s structure as it forms. Researchers report that this process refines the metal’s crystal structure and shrinks crystal size by nearly five times. Chelyabinsk-based local media initially covered the research in early October.
Denser welds resist vibration and mechanical stress
Ultrasonic treatment also reduces the thickness of the brittle intermetallic layers by half and removes air bubbles from the weld, resulting in more compact and resilient joints. Testing revealed that the strength of these joints doubled with the new method, and the longevity of components increased by 90%, matching the 1.9-fold improvement reported by SUSU. The researchers believe these enhancements could improve resistance to prolonged vibration and mechanical stress.
These findings suggest advantages for parts subjected to constant movement and heavy loads. According to SUSU, joints treated with this technique can endure long-term vibrational forces without cracking, which is especially relevant for vehicles and aircraft, where repeated stress occurs during operation. The results were shared through TV BRICS and reported by the university.
Enabling lighter constructions for automotive, aerospace, and infrastructure sectors
The researchers indicated that this technology could be applied within the automotive, aerospace, and construction industries. Combining steel with aluminium allows manufacturers to produce lighter yet strong structures. The university pointed out that lightweight bodies for electric vehicles could benefit from this method. In aviation, joining aluminium and steel components can reduce the overall weight of structures.
This project exemplifies ongoing scientific collaboration between Russian and Chinese experts. Stronger joints between dissimilar metals could enable the production of lighter, more durable components. The technique holds potential for creating structures that combine steel’s strength with aluminium’s light weight. Details regarding commercial implementation were not included in the reports.