Addis Ababa, October 19, 2026 (FMC) — Scientists from Russia and China have developed an ultrasonic welding technology that doubles the strength of metal joints and extends component service life by 1.9 times, opening new possibilities for manufacturing lighter and more durable products.
TV BRICS reported the development, citing information published on the website of South Ural State University (SUSU), a TV BRICS partner.
The researchers developed a method for joining metals with different properties, such as steel and aluminium. Conventional welding can create a hard but brittle layer at the junction of dissimilar metals, making the joint vulnerable to cracking under mechanical stress.
The new technique introduces ultrasonic waves with a power of around 1,200 watts into the spot-welding process. The vibrations refine the metal crystals in the weld, reducing their size by nearly five times and cutting the thickness of brittle interfacial layers by half. They also help remove air bubbles, producing a denser joint.
Tests showed that the technology doubled joint strength and increased component service life by a factor of 1.9. Researchers estimate that components made using the method could withstand prolonged vibration without developing cracks.
The technology could have applications across several industries. In automotive manufacturing, it could enable stronger, lighter vehicle bodies made from different metals, while reducing vehicle weight could help electric vehicles conserve battery energy.
In aviation, lighter components could reduce fuel consumption and create opportunities to increase passenger or cargo capacity. The method could also improve the reliability of metal connections used in buildings and bridges.
By improving the durability of joints between dissimilar metals, the technology could support the development of new products and more efficient engineering solutions.