MOSCOW, Russia / EuroWire.IO / – A novel ultrasonic welding approach created through collaboration between Russian and Chinese scientists can enhance the durability of metal parts by 1.9 times. According to South Ural State University, this method also doubles the strength of welded connections. The university, based in Chelyabinsk, developed the process alongside colleagues from China. The findings were reported by TV BRICS on October 19, citing the university. This technique is tailored for metals with differing characteristics.
A typical example of such a metal pair is steel and aluminium. Welding these metals often results in the formation of brittle layers at the joint, which can cause fractures under vibration and repeated stress. The new method mitigates this issue by improving the weld structure during spot welding. The university stated that the research appeared in the journal Engineering Fracture Mechanics, but did not specify individual researchers involved.
During the process, ultrasonic waves with approximately 1,200 watts of power are applied as the spot weld forms. Rossiyskaya Gazeta reported that these waves are transmitted via heating electrodes. The vibrations disrupt the crystal structure of the metal, causing the crystal size in the weld to shrink nearly fivefold, according to the university. Additionally, the brittle layers at the joint become half as thick. These structural modifications result in a more uniform weld that is less susceptible to cracking.
Denser welds resist vibrations more effectively
The ultrasonic waves also eliminate trapped air bubbles within the metal, producing a denser weld. Testing revealed that these joints are twice as strong, with the component lifespan increasing by 90%. The researchers highlighted that these parts can endure constant vibration and mechanical stress longer without developing cracks. This capability is particularly relevant for vehicles, aircraft, and infrastructure subjected to repetitive loads, as fatigue cracking at welds is a common cause of failure.
The university’s announcement emphasizes the relative improvements but does not provide absolute strength measurements, alloy specifications, or the number of samples tested. Several materials-related research initiatives have been reported by Russian universities this year, including projects on coatings for titanium implants materials research. South Ural State University has also developed a berberine-enriched cheese aimed at enhancing immunity. No timeline for commercial application has been provided by the university.
Potential uses in transportation and construction fields
The scientists foresee applications in automotive, aerospace, and construction industries. For example, car manufacturers could integrate steel passenger cells with aluminium doors, bonnet, and wings into a single hybrid body, resulting in a lighter vehicle capable of traveling further per charge. Similarly, aircraft producers could design lighter airliners with increased passenger or cargo capacity, which would also lead to lower fuel consumption per flight.
In construction, this welding method could be employed in bridges and high-rise buildings, with welded joints potentially surpassing the strength of monolithic concrete. Other applications include attaching steel columns to aluminium panels or welding steel longerons to aluminium subframes. This project was a joint effort between Russia and China. The university stated that this technique paves the way for creating structures that are both lighter and stronger across various sectors.