MOSCOW, Russia / EuroWire.IO / – A recently developed ultrasonic welding technique by scientists from Russia and China can increase the lifespan of metal components by 1.9 times. According to South Ural State University, this method also doubles the strength of welded joints. Researchers at the Chelyabinsk-based university collaborated with colleagues from China to create this process, which was reported by TV BRICS on October 19, citing the university. It is specifically designed for metals with differing properties.
Common combinations such as steel and aluminium often experience brittle layer formation at the joint during welding, which can cause fractures under vibration and repeated stress. The innovative technique mitigates this issue by enhancing the weld’s structure during spot welding. The university stated that the research appeared in the journal Engineering Fracture Mechanics, but did not specify the individual researchers involved.
During the process, ultrasonic waves with a power of approximately 1,200 watts are applied as the spot weld is formed. According to Rossiyskaya Gazeta, these waves are transmitted through heating electrodes, causing the crystal structure of the metal to break down. The university noted that the crystal size within the weld reduces by almost five times, and 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 vibration
Ultrasound also eliminates air bubbles in the metal, leading to a denser, stronger weld. Testing demonstrated that the joints are twice as durable, with the service life of the components increasing by 90%. The researchers highlighted that these parts can endure continuous vibration and mechanical loads longer without developing cracks, a crucial benefit for vehicles, aircraft, and structures subjected to repeated stress. Fatigue cracking at welds is a common failure cause in many components.
The university’s report provided relative improvements but did not specify actual strength measurements, alloy types, or the number of samples tested. This year, Russian universities have announced several materials research projects, including coatings for titanium implants. South Ural State University also developed a berberine-enriched cheese intended to bolster immunity. The university has not provided a timeline for commercial application.
Potential uses in transportation and construction
The scientists envisage applications across automotive, aerospace, and building industries. For instance, car manufacturers could create a hybrid body combining a steel passenger cell with aluminium doors, bonnet, and wings. Such a lighter structure would improve the range of electric vehicles. In aerospace, lighter airliners could be built to carry more passengers or cargo, and would consume less fuel per flight.
In construction, the welding method could be employed in bridges and skyscrapers, with welded joints potentially surpassing the strength of monolithic concrete. Examples include joining 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, and the university emphasized that the technique paves the way for lighter, more durable structures in various sectors.