Progressive effect of dual-hybridization in friction stir welding by ultrasonic vibration and resistive heating for joining dissimilar material Al6063 aluminium alloy and C26000 copper alloy

Abstract

In the world of disruptive technology, Al–Cu joints are quite in demand for electric vehicle batteries and other ion battery applications. Fusion welding is the less preferred method due to its many disadvantages; friction stir welding has the potential to become a sustainable process for producing a sound dissimilar Al–Cu joint. A study of multiple hybridization to the Friction Stir Welding (FSW)was made by utilizing two different energy sources of ultrasonic energy and electric current. The improvement is the property by different combination 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. Mechanical properties obtained by varying the process parameters have been studied and compared. Three process parameters have been selected including ultrasonic energy (10 KHz), electric current (75–125 Amps), rpm (400–600 rpm) and transverse tool rate (30–50 mm/min). A remarkable improvement in the mechanical property has been monitored by adding electric current to the UAFSW. Similar optimistic results in the improvement of the property have been found by adding Ultrasonic energy to RHFSW. The comparative study in the mechanical property had been presented to explain the improvement in the weld efficacy.