Russian and Chinese scientists develop ultrasonic welding method

Researchers from South Ural State University (SUSU) in Russia and partners in China have developed a new ultrasonic welding technology that doubles the strength of metal joints. The method is specifically designed to join dissimilar metals, such as steel and aluminium, which traditionally face challenges due to the formation of brittle intermetallic layers at the connection point.

By applying ultrasonic waves with approximately 1,200 watts of power during spot welding, the process refines the metal’s crystal structure and reduces crystal size by nearly fivefold. This technique also halves the thickness of brittle layers and removes air bubbles, resulting in denser, more durable joints.

According to the university, the new method increases the service life of welded components by 1.9 times. These improvements in resistance to vibration and mechanical stress make the technology particularly relevant for components used in vehicles, aircraft, and buildings that are subject to constant movement and heavy loads.