Progressive Effect of Dual-Hybridization in Friction Stir Welding by Ultrasonic Energy and Electric Current for Joining Dissimilar Material Al6063 Aluminum Alloy and C26000 Copper Alloy

Friction Stir Welding (FSW) has become a trusted method for joining softer alloys like Aluminum and copper. However, for achieving improved joint efficiency and dissimilar joints, secondary heat sources are being used to make the materials softer to enhance the mixing through stirring. In this present work, a comparative study of multiple hybridization techniques to Friction Stir Welding was performed by utilizing two different energy sources viz. resistive heating through electric current and ultrasonic energy (UE). Different combinations of the hybridization studied for utilizing the multiple hybridization technique to the FSW process for improving the weld efficacy and defects-free weld even in case of dissimilar joints. A comparative study of the mechanical properties obtained by varying the process parameters have been performed. Three process parameters have been selected including UE (10 kHz), electric current (75–125 Amps), tool rotational speed (400–600 rpm), and tool transverse rate (30–50 mm/min). A significant improvement in the mechanical behavior has been monitored by adding electric current to the UAFSW by an in-house developed fixture. Similar optimistic results in the improvement of the property have been found by adding UE to EAFSW. A comparative study in the mechanical property has been presented to explain the improvement in the property. Microstructure study was also performed to analyze the behavior of Al–Cu joint.