MOSCOW, Russia / EuroWire.IO / – In recent developments, a novel ultrasonic welding approach created through collaboration between Russian and Chinese researchers has demonstrated the ability to prolong the lifespan of metal parts by a factor of 1.9. According to South Ural State University, this innovation also enhances the durability of welded joints, doubling their strength. The university’s scientists from Chelyabinsk partnered with Chinese colleagues to develop this process, which is suitable for metals with varying properties, the university reported on October 19 via TV BRICS. The technique is tailored to work with dissimilar metals.
In the context of common pairings such as steel and aluminium, welding these metals often results in the formation of brittle layers at the joint. Such layers can cause fractures, especially under conditions of vibration and repetitive mechanical loads. The new method minimizes this risk by refining the weld structure during spot welding. The university indicated that the research findings were published in the journal Engineering Fracture Mechanics, though no specific researchers’ names were disclosed in the announcement.
During the process, ultrasonic waves with an output of approximately 1,200 watts are applied as the spot weld takes shape. According to Rossiyskaya Gazeta, these waves are transmitted through the heating electrodes. The vibration disrupts the metal’s crystal lattice, leading to a reduction in crystal size by nearly five times, as stated by the university. Additionally, the brittle layers at the joint are reduced to half their original thickness. These structural modifications contribute to a more uniform weld that resists cracking more effectively.
Denser welds offer greater resistance to vibration
The ultrasonic application also expels trapped air bubbles within the metal, resulting in a more compact weld. Laboratory tests have shown that such joints are twice as strong. The lifespan of the assembled parts increased by 90%. The researchers emphasized that these components can endure prolonged exposure to vibrations and mechanical stresses without developing cracks. This improvement is particularly significant for automotive, aerospace, and structural applications where repeated load cycles often lead to fatigue cracks at welds, causing failure.
The announcement from South Ural State University highlighted the relative improvements, but did not specify absolute strength measurements, specific alloy types, or the number of samples tested. Earlier this year, Russian universities reported several materials research initiatives, including coatings for titanium implants. Additionally, South Ural State University has created a berberine-enriched cheese aimed at boosting immunity. The timeline for potential industrial implementation of this welding method remains unspecified.
Potential uses in transportation and construction sectors
Looking ahead, the researchers see promising applications across automotive, aerospace, and building industries. For example, automakers could create a hybrid structure by joining a steel passenger compartment with aluminium doors, bonnet, and wings, resulting in a lighter vehicle that can travel farther on a single charge. In the aerospace domain, manufacturers might produce lighter aircraft capable of carrying increased passenger or cargo loads, leading to reduced fuel consumption per flight.
In construction, the technique could be employed to assemble bridges and skyscrapers, with welded joints potentially surpassing the strength of monolithic concrete. Additional applications include connecting a steel column to an aluminium panel or welding a steel longeron to an aluminium subframe. This research was conducted as a joint project between Russia and China. The university stated that this approach paves the way for developing lighter, stronger structures across multiple industries.