MOSCOW, Russia / EuroWire.IO / – A recently developed ultrasonic welding approach by Russian and Chinese researchers can extend the lifespan of metal parts by 1.9 times. This method also doubles the tensile strength of the welds, according to South Ural State University. The university’s scientists collaborated with colleagues from China to create this process. The findings were reported by TV BRICS on October 19, referencing the university. The technique is effective for metals with varying characteristics.
For example, steel and aluminium are frequently paired metals. When these metals are welded, brittle layers often form at the joint. Such layers can cause fractures under vibrations or repeated stress. The new method minimizes this risk by improving the weld structure during spot welding. The university stated that the research was published in the journal Engineering Fracture Mechanics. No specific researchers’ names were disclosed in their announcement.
The process involves applying ultrasonic waves of approximately 1,200 watts while forming the spot weld. Rossiyskaya Gazeta reported that these waves are delivered through heating electrodes. The vibrations disrupt the crystal structure of the metal. According to the university, the crystal size in the weld reduces by nearly five times. The brittle layers at the joint become half as thick. These structural changes lead to a more uniform weld that is less susceptible to cracking.
Denser welds resist vibration and fatigue
Ultrasound also eliminates air bubbles from the metal, resulting in a denser weld. Testing showed that the joints are twice as strong. The lifespan of the components increased by 90%. The researchers highlighted that these parts can endure continuous vibration and mechanical stress longer without developing cracks. This improvement is significant for vehicles, aircraft, and structures that experience repeated loading. Fatigue cracking at welds is a common cause of component failure.
The university’s announcement focused on the relative improvements. It did not specify absolute strength measurements, alloy types, or the number of samples tested. This year, Russian universities have reported several materials research projects, including coatings for titanium implants. South Ural State University has also developed a berberine-enriched cheese aimed at supporting immunity. The university did not provide a timeline for commercial application.
Potential uses in transportation and construction sectors
The scientists see opportunities in automotive, aerospace, and building industries. Car manufacturers could combine steel passenger cabins with aluminium doors, hoods, and wings into a single hybrid structure. Such a lighter body could enable electric vehicles to travel farther on a single charge. Aircraft producers might construct lighter airliners capable of carrying more passengers or cargo. Reduced weight would also lead to lower fuel consumption per flight.
In construction, the technique could be used for bridges and high-rise buildings. The university claims welded joints could be stronger than monolithic concrete. Other examples include connecting a steel column to an aluminium panel. A steel longeron could also be welded to an aluminium subframe. This project was a joint effort between Russia and China. The university believes the new method can lead to lighter, more durable structures across various sectors.