MOSCOW, Russia / EuroWire.IO / – In Chelyabinsk, South Ural State University announced on October 19 that a novel ultrasonic welding approach created by scientists from Russia and China can extend the durability of metal parts by nearly 1.9 times. The innovation also doubles the joint strength, as reported by TV BRICS and the university. This method is tailored for metals exhibiting different physical properties.
Common examples include steel and aluminium, which often form brittle layers at their weld interfaces. These layers pose a risk of fractures under vibrations and cyclic loads. The new technique mitigates this issue by enhancing the weld structure during spot welding. According to the university, the findings were published in the journal Engineering Fracture Mechanics, with no specific researchers named in the release.
The process involves applying ultrasonic waves at approximately 1,200 watts during the formation of the spot weld. Rossiyskaya Gazeta reports that these waves are transmitted through heating electrodes. The vibrations disrupt the metal’s crystal lattice, reducing crystal size in the weld by nearly five times. This results in the brittle layers at the joint becoming half as thick, producing a more uniform weld that is less susceptible to cracks.
Denser welds better resist vibrations
Ultrasound also helps eliminate trapped air bubbles within the metal, leading to denser welds. Testing revealed that these joints are twice as strong and that the service life of the parts increases by 90%. The researchers note that components can endure prolonged vibration and mechanical stresses without developing cracks, which is crucial for vehicles, aircraft, and structures subjected to repeated loading cycles. Fatigue cracks at weld points are a frequent cause of component failure.
The university provided relative performance improvements but did not specify absolute strength values, alloy types, or the number of samples tested. Earlier this year, Russian institutions reported multiple materials research initiatives, including work on titanium implant coatings. South Ural State University has also created a berberine-enriched cheese aimed at boosting immunity. No timeline for industrial implementation was provided.
Potential uses in automotive, aerospace, and construction industries
The scientists see promising applications across automotive, aerospace, and construction sectors. For example, car manufacturers could integrate a steel passenger cell with aluminium doors, bonnet, and wings into a unified hybrid structure. Such a lightweight design could enable electric vehicles to achieve longer distances per charge. Similarly, aircraft manufacturers could develop lighter airliners capable of transporting more passengers or cargo, with reduced fuel consumption per flight.
In construction, this welding technique could be used in bridges and skyscrapers. The university suggests that welded joints might surpass the strength of monolithic concrete. Additional applications include attaching a steel column to an aluminium panel or welding a steel longeron to an aluminium subframe. This research was a collaborative project between Russia and China. The university emphasizes that this method paves the way for lighter, stronger structures across numerous industries.