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.
Joining steel and aluminium has long posed a challenge for manufacturers. When the two metals are welded, brittle intermetallic layers can form at the joint. These hard layers can act as stress concentration zones and reduce the durability of the connection under load. The new technique aims to limit those weak points and lower the risk of fractures at the joint. SUSU is based in the Russian city of Chelyabinsk.
The team introduced ultrasonic waves with a power of around 1,200 watts during spot welding. The vibration acts directly on the metal as the welded joint forms and changes the structure of the weld. According to the researchers, the process refines the metal’s crystal structure and reduces crystal size by nearly fivefold. Local media in Chelyabinsk first reported on the research earlier in October.
Denser welds withstand vibration and stress
The ultrasonic treatment also halves the thickness of the brittle layers that form between the metals. It removes air bubbles from the weld, producing denser and more durable joints. Tests showed that joint strength doubled with the new process. The service life of components increased by 90%, equal to the 1.9-fold gain reported by the university. The researchers said the improvements could boost resistance to prolonged vibration and mechanical stress.
The results point to potential gains for parts exposed to constant movement and heavy loads. According to the university, joints treated with the method can withstand constant vibrational loads for a long time without cracking. Such durability matters in vehicles and aircraft, where components face repeated stress during operation. The findings were reported by the university and shared through TV BRICS.
Lighter structures for cars, aircraft and buildings
The researchers said the technology could be used in the automotive, aerospace and construction industries. Combining steel and aluminium allows manufacturers to reduce the weight of structures while keeping them strong. The university highlighted lightweight bodies for electric vehicles as one possible use. In aviation, joining aluminium and steel parts can help cut the overall mass of structures.
The project reflects ongoing scientific cooperation between Russian and Chinese researchers. Stronger joints between dissimilar metals could help manufacturers produce lighter and more durable components. The method could support structures that combine the strength of steel with the low weight of aluminium. Details of commercial deployment were not included in the reports.