MOSCOW, Russia / EuroWire.IO / – A new ultrasonic welding method developed by Russian and Chinese scientists can make metal parts last 1.9 times longer. The technology also doubles the strength of welded joints, according to South Ural State University. Researchers at the Chelyabinsk-based university developed the process together with colleagues from China. TV BRICS reported the findings on October 19, citing the university. The method is designed for metals with different properties.
Steel and aluminium are a common example of such a pairing. When the two metals are welded, brittle layers often form at the joint. These layers can lead to fractures, especially under vibration and repeated loads. The new method reduces that risk by refining the structure of the weld during spot welding. The university said the research was published in the journal Engineering Fracture Mechanics. Its announcement did not name individual researchers.
The process applies ultrasonic waves with a power of around 1,200 watts while the spot weld is formed. Rossiyskaya Gazeta reported that the waves are applied through the heating electrodes. The vibration breaks up the crystal structure of the metal. Crystal size in the weld shrinks by nearly five times, the university said. The brittle layers at the joint become half as thick. Together, the changes make the weld more uniform and less prone to cracking.
Denser welds withstand vibration
Ultrasound also removes air bubbles from the metal, producing a denser weld. In tests, the joints proved twice as strong. The service life of the components rose by 90%. The researchers said the parts can withstand constant vibration and mechanical stress for longer without cracks. Such performance matters for vehicles, aircraft and structures exposed to repeated loads. Fatigue cracking at welds is a common cause of component failure.
The university’s announcement gave the gains in relative terms. It did not list absolute strength values, alloy grades or the number of samples tested. Russian universities have reported several materials research projects this year, including work on coatings for titanium implants. South Ural State University has also developed a berberine-enriched cheese designed to support immunity. The university did not give a timeline for industrial use.
Applications in transport and construction
The researchers see uses in the automotive, aerospace and construction sectors. Car makers could join a steel passenger cell with aluminium doors, bonnet and wings in a single hybrid body. A lighter body would allow electric cars to cover more distance per charge. Aircraft makers could build lighter airliners able to carry more passengers or cargo. Lighter aircraft would also burn less fuel on each flight.
In construction, the technique could be applied to bridges and tall buildings. The university said the welded joints could prove stronger than monolithic concrete. Other examples cited include joining a steel column to an aluminium panel. A steel longeron could also be welded to an aluminium subframe. The work was carried out as a joint Russia-China project. The university said the method opens the way to lighter and stronger structures across several industries.