Fusion Welding Research Articles

Application of Pattern Search and Genetic Algorithms to Optimize HDPE Pipe Joint Profiles and Strength in the Butt Fusion Welding Process

The rapid spread of the use of high-density polyethylene (HDPE) pipes is due to the wide variety of methods for connecting them. This study keeps pace with the developments of butt fusion welding of HDPE pipes by exploring the relationship between the performance of the weld joints by studying ultimate tensile strength and exploring the joint welding profiles by studying the shape of the joint at the outer surface of the pipe (height and width of the joint cap) and the shape of the joint at the internal surface (height and width of the joint root). Welding pressure, heater temperature, stocking time, and cooling time were the parameters for the welding process. Regression was analyzed using ANOVA, and an ANN was used to analyze the experimental results and predict the outputs. Two optimization techniques (pattern search and genetic algorithm) were applied to obtain the ideal operating conditions and compare their performance. The results showed that pattern search and genetic algorithms can determine the optimal output results and corresponding welding parameters. In comparison between the two methods, pattern search has a limited relative advantage. The optimal values for the obtained outputs revolved around a tensile strength of 35 MPa (3.45 and 4.5 mm for the cap and root heights, and 8 and 6.98 mm for the cap and root widths, respectively). When comparing the effects of welding parameters on the results, welding pressure had the best effect on tensile strength, and plate surface temperature had the most significant effect on the welding profile geometries.

Insights into the microstructural evolution and strengthening mechanisms of friction stir spot welded advanced high strength ultrafine bainitic steel

Unlocking the full potential of advanced high-strength bainitic steels in spot-welding is a pivotal endeavor for harnessing their extraordinary mechanical properties in the automotive industry. This study suggests a shift in paradigm to address the inferior fusion weldability of this type of steel because of the formation of coarse martensite within the welded zone of weldments obtained by liquid-state welding, through the strategy of refining the martensite within the weld zone using the solid-state friction stir spot welding (FSSW) process. This paper delves into an in-depth investigation of the microstructural evolution and load-bearing capacity of a Fe-0.25C-3Cr-1.63Mn-1.5Si (wt%) ultrafine bainitic steel, having a remarkable tensile strength of 1.7 GPa, during the intriguing process of FSSW at rotational speeds of 600 to 2000 rpm. The research uncovers that the stir zone (SZ) undergoes dynamic recrystallization, resulting in a significantly refined microstructure. Regardless of the rotational speed employed, the high hardenability of the steel and rapid cooling during the process inevitably results in martensite formation within this region. However, a comprehensive microstructural characterization conducted by the electron backscatter diffraction (EBSD) analysis proves that the different thermal cycles induced by different rotational speeds lead into various prior austenite grain sizes, martensitic/bainitic packets and blocks attributes, and density of high-angle grain boundaries (HAGBs). Through the evaluation of strengthening mechanisms in different weld zones, the study sheds light on the key factors influencing strength. Block boundaries emerge as the primary contributor to SZ hardening, surpassing the role of geometrically necessary dislocations (GNDs) and solid solution strengthening. The load-bearing capacity observed during the tensile-shear test is governed by a delicate interplay between bonding width and crystallographic features (block size and HAGBs density) of the martensite formed within the SZ. The highest peak load was achieved under optimal welding conditions (rotational speed of 1000 rpm), which enabled the production of a sufficiently large bonding width, providing ample bonding area for load-bearing, along with an abundance of blocks and HAGBs to effectively impeding crack propagation.

Grain Structure and Texture Evolution in the Bottom Zone of Dissimilar Friction-Stir-Welded AA2024-T351 and AA7075-T651 Joints.

High-strength dissimilar aluminum alloys are difficult to connect by fusion welding, while they can be successfully joined by friction stir welding (FSW). However, the asymmetrical deformation and heat input that occur during FSW result in the formation of a heterogeneous microstructure in their welded zone. In this work, the grain structure and texture evolution in the bottom zones of dissimilar FSW AA2024-T351 and AA7075-T651 joints at different welding speeds (feeding speeds) were quantitatively investigated. The results indicated that dynamic recrystallization occurs in the bottom zones of dissimilar FSW joints, and equiaxed grains with low grain sizes are formed at the welding speed of 60-240 mm/min. A high fraction of the recrystallized grains were generated in the bottom zones of the joints at a low welding speed, while a high fraction of the substructured grains are produced at a high welding speed. Different types of shear textures are produced in the bottom zones of the joints; the number fraction of shear texture types depends on different welding speeds. This study helps to understand the mechanism of microstructure homogenization in dissimilar FSW joints and provides a basis for further improving the microstructure of the welded zone for engineering applications.

Characteristics analysis and monitoring of friction stir welded dissimilar AA5083/AA6061-T6 using acoustic emission technique

The joining of aluminum alloys using fusion welding often leads to issues such as hot tears, porosity, distortion, and solidifying cracks. To address these challenges, solid-state welding processes like Friction Stir Welding (FSW) are preferable. This study investigates the FSW of dissimilar aluminum alloys AA 5083 and AA 6061-T6, employing Acoustic Emission (AE) techniques for real-time monitoring. FSW was conducted under conditions with no defects, pinhole defects, and piping defects. The resulting joints were evaluated for their mechanical properties and metallurgical characteristics. Microstructural analysis was performed using an optical microscope, revealing that the defect-free condition achieved the highest tensile strength of 256 MPa and superior hardness of 93 HV at the stir zone. Tensile failure commonly manifested within the heat-affected zone (HAZ) of AA 6061-T6, primarily due to grain enlargement and the impact of Mg2Si precipitates. Examination of the fractured regions via scanning electron microscopy revealed ductile-mode fractures featuring elongated dimples and microvoids. AE parameters such as hits, amplitude RMS, and energy were analyzed, demonstrating that defect-free welds had consistent AE signal patterns, while significant variations were observed in pinhole and piping defect conditions due to larger defect areas. The findings suggest that AE monitoring is effective in detecting and analyzing welding defects, providing valuable insights into the FSW process for dissimilar aluminum alloys.

Enhancing fusion welding in die-cast Mg alloys: A combined ultrasonic vibration and hot rolling approach for porosity reduction, microstructure refinement, and mechanical property improvement

Severe weld porosity has led the industry to believe that die-cast magnesium alloys cannot be fusion welded. To address this challenge, a new process of ultrasonic vibration coupled with hot rolling was employed to eliminate porosity, and the mechanism associated with weld porosity in die-cast magnesium alloys was analyzed in detail. Unlike conventional welding processes, ultrasonic vibration coupled with hot rolling is effective and efficient. In this study, a roller with ultrasonic vibrations is synchronized with the molten pool to apply pressure to the weld, which is in a semi-solid state on the upper surface. The results showed that hot rolling and ultrasonic vibration coupled with hot rolling could eliminate 78.12 % and 85.5 % of the porosity, respectively. Compared to hot rolling, the ultrasonic vibration coupled with the hot rolling process resulted in smaller and fewer porosities and finer β-Mg17Al12. This is attributed to the cavitation effect of ultrasonic vibration that promotes bubble overflow and breaks the β-Mg17Al12 dendrites in the melt pool, as well as the thermal effect that improves the plasticity of the weld. Furthermore, after closing the porosity under pressure, recrystallized grains will be produced around it. Tensile test results indicated that hot rolling was able to increase the ultimate tensile strength by 84.21 % and elongation by 44.03, whereas ultrasonic vibration coupled with hot rolling was able to increase the ultimate tensile strength by 244.46 % and elongation by 71.70 %. Combining the micron-scale industrial computed tomography results with theoretical calculations, it is found that the porosity of die-cast magnesium alloys is mainly caused by nitrogen, and they originate from gas entrapment during the die-casting process; further, the formation mechanism of die-cast magnesium alloys' fusion-welding porosity is revealed in detail. A physical model of the formation process of welded porosity morphology was established, and the analysis suggested that the pattern of the inner wall of the porosity was related to the Kelvin–Helmholtz instability. This research is expected to improve the weld quality of alloys manufactured by the die-casting process.

Tensile strength optimisation in AA2014 aluminum alloy joints via friction stir welding: a rivet-free approach examining materials flow behaviour

ABSTRACT Steel rivets are alternative materials for connecting materials for structural fabrication industry. The use of rivets may significantly increase the structure weight, impacting its overall performance. Additionally, there is a risk of inducing corrosion at the interface due to galvanic coupling. Therefore, careful consideration of material choices and potential consequences is necessary during the design and fabrication processes. When joining dissimilar alloys, manufacturers and designers face numerous challenges with conventional fusion welding techniques. Friction stir welding is effective at joining materials without reaching their melting points; instead, it relies on severe plastic deformation and recrystallization to create a welded joint. Proper selection of the tool and process parameters is crucial for achieving a sound weld result. The results from experimental investigations highlight the significance of plastic deformation, material flow, and recrystallization as influential factors on joint strength. This finding suggested that FSW is an ideal joining process for high-strength alloys. Although friction stir welding is a suitable alternative to permanent joints, such as rivets, notably, the experimental findings reveal that friction stir welding of both but and lap joints yields maximum load-carrying capabilities of 50.5 and 51.2 kN, respectively, emphasising the efficacy of the method in structural applications

Comparison between Mechanical Properties and Joint Performance of AA 2024-T351 Aluminum Alloy Welded by Friction Stir Welding, Metal Inert Gas and Tungsten Inert Gas Processes.

The aim of this work is to study joining Al 2024-T3 alloy plates with different welding procedures. Aluminum alloy AA 2024-T351 is especially used in the aerospace industry. Aluminum plates are welded by the TIG and MIG fusion welding process, as well as by the solid-state welding process, friction stir welding (FSW), which has recently become very important in aluminum and alloy welding. For welding AA2024-T35 with MIG and TIG fusion processes, the filler material ER 4043-AlSi5 was chosen because of reduced cracking. Different methods were used to evaluate the quality of the produced joints, including macro- and microstructure evaluation, in addition to hardness and tensile tests. The ultimate tensile strength (UTS) of the FSW sample was found to be 80% higher than that of MIG and TIG samples. The average hardness value of the weld zone of metal for the MIG- and TIG-produced AA2024-T3511 butt joints showed a significant decrease compared to the hardness of the base metal AA2024-T351 by 50%, while for FSW joints, in the nugget zone, the hardness is about 10% lower relative to the base metal AA2024-T3511.

Microstructural Analysis and Microhardness Evaluation of Stainless Steel SS304 Joints Utilizing Microwave Hybrid Heating (MHH) and Cold/Heat Processing: A Fuzzy Logic Approach

Stainless steel SS304 is extensively used in dental applications for its high strength, hardness, and corrosion resistance. However, Conventional dental joining techniques such as soldering and fusion welding, reliant on elevated temperatures and toxic fluxes, present substantial oral health risks, leading to potential health deterioration due to toxic emissions. The study proposes the utilization of a microwave hybrid heating process (MHH) for joining stainless steel SS304 (15mm × 7.9mm × 0.2mm) and pure zinc metal powder (44 µm, 99% purity), citing its enhanced efficiency, speed, precision, and diminished environmental footprint as key characteristics without fume. It explores heat processing between 30°C to 60°C and cold temperature processing from 0°C to 10°C to analyze alterations in hardness properties and microstructures. The study identified a direct correlation between temperature and microhardness, observing an increase in microhardness with rising temperatures. Optimal microhardness of 208.6 HV was achieved at 60°C during a 3 min heat treatment. Cold temperatures induced slight deformation and grain transformation, while heat treatment enhanced grain density and hardness, particularly in the strongly bonded boundary layer, with experimental and predicted values using Fuzzy logic showing promising outcomes and errors below 10%. In conclusion, the study demonstrates that achieving a specific hardness value in stainless steel joints is highly desirable for dental applications, alongside the observation of favorable microstructures. These findings underscore the potential of MHH to propel dental technology forward and promote sustainable practices while addressing environmental concerns.

Elucidating the influence mechanisms of splat cooling on microstructure evolution in friction stir welding of 2195 Al–Li alloy by multi-scale simulation

Al–Li alloy has been widely used in the manufacture of aerospace aircraft structural parts due to its high specific strength and excellent comprehensive performance. Friction stir welding (FSW), as a solid-state joining technique, generates comparatively lower heat generation in contrast to fusion welding. However, even with this reduced heat input, the welded joints of 2195 Al–Li alloy still exhibit noticeable thermal softening. FSW is very sensitive to welding heat input, and the thermal cycle of high peak temperature coarsens the grain in the weld zone, thereby reducing joint properties. To overcome these problems, external cooling can be applied to reduce peak temperature and increase cooling speed, improving the performance of FSW joints. In order to study the mechanism of external cooling on the microstructure evolution of joints, this work established a multi-scale simulation of splat cooling assisted friction stir welding (SCaFSW) of 2195 Al–Li alloy. The temperature change and material deformation data in SCaFSW were calculated in the macroscopic finite element model and used for further Monte Carlo microstructure evolution simulation, and compared with the conventional FSW process. Results reveal that the splat cooling significantly reduces the area of the high temperature region of the workpiece, decreasing the temperature at the same location 10 mm behind the tool by approximately 50 °C compared to FSW. While the local temperature field around the tool pin is not affected by the splat cooling, which mainly accelerates the cooling rate of the welded joint and reduces the plastic strain. In addition, the dislocation density in the weld nugget zone (WNZ) of SCaFSW joint is higher than that in conventional FSW, which promotes the process of grain nucleation and finally refines the grain in the WNZ. The simulated average grain size and thermal cycling results are in good agreement with the experimental results.

Friction Stir Welding Benefits Technique over Other Welding Techniques of Dissimilar Metals

Abstract: Due to the low heat input situation, solid state welding (SSW) has demonstrated higher potential for integrating a variety of equivalent and dissimilar material combinations. The temperature stays below the melting point of the source materials throughout the solid-state welding process. Compared to fusion welding, solid state welding offers the highest quality. Aeronautics, nuclear, space, and aviation are just a few of the industrial production sectors that utilize the solid-state welding technology. Diffusion welding, explosion welding, friction welding, forge welding, cold welding, role welding, hot pressure welding, and ultrasonic welding are just a few of the SSW techniques covered in the current article. This study looks at a variety of SSW kinds and solid-state welding applications. This study examines many types of SSW and the applications of solid-state welding. Current Study includes the pros and cons of other welding techniques over friction stir welding.

Friction Stir Welding Benefits Technique over Other Welding Techniques of Dissimilar Metals

Abstract: Due to the low heat input situation, solid state welding (SSW) has demonstrated higher potential for integrating a variety of equivalent and dissimilar material combinations. The temperature stays below the melting point of the source materials throughout the solid-state welding process. Compared to fusion welding, solid state welding offers the highest quality. Aeronautics, nuclear, space, and aviation are just a few of the industrial production sectors that utilize the solid-state welding technology. Diffusion welding, explosion welding, friction welding, forge welding, cold welding, role welding, hot pressure welding, and ultrasonic welding are just a few of the SSW techniques covered in the current article. This study looks at a variety of SSW kinds and solid-state welding applications. This study examines many types of SSW and the applications of solid-state welding. Current Study includes the pros and cons of other welding techniques over friction stir welding

Investigating microstructure, mechanical properties, and pitting corrosion resistance of UNS S32760 super duplex stainless steel after linear friction welding

High-performance alloys such as super duplex stainless steels (SDSS) are of interest to the oil and gas industry, especially in deep and ultra-deep reservoirs where high pressures and highly corrosive environments are prevalent. SDSS have high nitrogen contents and pitting resistant equivalent number (PREN) values greater than 40, however, fusion welds of these alloys can exhibit unsuitable microstructures and defects that may result in failure during usage. Solid-state linear friction welding (LFW) offers an alternative for the effective joining of SDSS with a less detrimental effect on microstructure and properties. In this work, four LFW joints in UNS S32760 SDSS were produced and investigated by evaluating the process parameters required to achieve a high-quality joint with the desirable metallurgical, mechanical, and localized corrosion properties. These properties were assessed through metallography (optical microscopy and scanning electron microscopy), tensile and microhardness tests, and corrosion analysis according to the ASTM G48A standard. Results indicated that one specific combination of LFW parameters led to a defect-free joint, and that the mechanical properties of the weld in this case were comparable to those of the base material. Additionally, an adequate balance between ferrite and austenite phases was achieved throughout the microstructural gradients seen in the weld region. Microhardness values were below 350 HV, thus complying with the DNV–OS–F101 standard. Furthermore, no pitting corrosion was observed in this joint under the testing conditions suggested by ASTM G48A.

Investigation of Creep Behavior of HDPE Pipe Butt Fusion Welded Joints Using a Stepped Isostress Method.

The utilization of high-density polyethylene (HDPE) pipes is prevalent in water transportation due to their exceptional durability, resistance to corrosion, and ease of installation. Traditionally, butt fusion welding has been employed to connect HDPE pipes. In this study, scanning electron microscopy (SEM) was utilized to examine the microstructure of butt fusion welded joints of HDPE pipes, while the stepped isostress method (SSM) was employed to investigate their creep behavior at 100 °C in ambient air. SEM results revealed a significant presence of craze or lamellae in the base material, whereas minimal occurrences of craze or lamellae were observed in the melt zone. The results obtained from the SSM indicated that the creep life of butt fusion welded joints of HDPE pipes was not adversely affected by the welding bead, and their creep life was no less than that of the base material when ductile creep failure occurred.

Joining of Al-Alloy Tubes by Carbon Steel Tubes using MPW Technique

Background/ Objectives: Joining aluminum alloys with low carbon steel (DC01) through fusion welding is a challenging task due to the occurrence of solidification defects like porosity, alloy segregation, and hot cracking. However, these issues can be addressed by employing solid-state welding techniques like explosive welding and MPW (magnetic pulse welding). MPW is a cost-effective and high-speed solid state welding method that involves creating joints in an overlap configuration. Methods: The MPW technique was employed to join dissimilar aluminum alloy AL 7075T6 hollow tube and DC01 steel rod in this study. A central composite design model was created to analyze the relationship between key MPW process parameters, including stand-off distance (SoD), overlap length, and discharge energy, and the bonding strength of the joints. Experimental setups were established and correlate with tensile-shear fracture load and interface hardness of the joints with the MPW process parameters. Findings: It is understood that the maximum TSFL of 2.404 kN was obtained under the welding condition of 23kJ discharge energy, 2.25 mm Stand-off distance, 8.5 mm overlap length, which is the optimum MP welding state for AA 7075 T6 with DC01 and confirmed by RSM. In addition, the cultivated connection can be aptly leveraged to anticipate the TSFL of MPW joints with a 95% confidence level. Novelty: The parametric mathematic samples were developed for forecasting TSFL of joints. The MPW parameters were optimized to enhance TSFL of joints. Aluminium alloys with low carbon steel joints were developed using MPW for cars and ships applications without fusion welding defects. Keywords: Magnetic Pulse Welding, Dissimilar Joint, (RSM) Response Surface Methodology, Tensile Shear-Fracture Load

Microstructure and strengthening mechanism of TIG welded joint of AZ31 alloy based on FSP technique

Magnesium alloys, renowned for their outstanding properties, present promising applications within the realm of advanced manufacturing. Addressing the challenges of coarse grains and inferior properties in the fusion welding of magnesium alloys, a novel strengthening approach for fusion-welded joints is proposed in this study. This method employs fine, uniform, and dense grains as the matrix, with particle-reinforced structures serving as the strengthening backbone. By utilizing powder feeding in conjunction with fusion welding and friction stir processing, ideal microstructures were successfully fabricated, and the mechanisms influencing grain morphology and joint properties were explored. Following the strengthening treatment, the grain size of the magnesium alloy molten weld was reduced from 193.5 μm to 15.9 μm, resulting in a grain refinement efficacy of 91.8 %. Concurrently, the tensile strength was augmented by 70.2 MPa, and the elongation experienced a 136 % enhancement. The grain morphology, eutectic phase structure, texture strength, precipitated phase type and dislocation distribution at each processing stage of the welded joint were observed. Research shows that nano-enhanced particles adhere to the eutectic structure of grain boundaries, effectively inhibiting the diffusion of solute elements and significantly reducing the dendrite growth rate. It is the main mechanism by which reinforced particles lead to grain refinement. Discontinuous recrystallization during FSP treatment leads to grain refinement, work hardening and enhanced pinning of particles at grain boundaries, which are the main reasons for the strength improvement.

Coupling influence of laser-Nb interlayer on microstructure and performance of Ti/Al joint

Laser fusion welding of TC4 titanium (Ti) alloy and aviation 7075 aluminum (Al) alloy was conducted with the assistance of a niobium (Nb) interlayer. The effect of laser heat input and the alloying effect of Nb on the interfacial layer was analyzed. The study also investigated the coupling influence of the laser-Nb interlayer on the microstructure and performance of the Ti/Al joint. By utilizing a 0.1 mm-thick Nb interlayer and a welding velocity of 1800 mm/min, the results reveal an initial increase in tensile-shear force followed by a decline with the increase of laser power. The tensile-shear force reached a peak of 1663 N at 1.2 kW, representing a 36.76 % improvement over the 1 kW levels. Under appropriate laser power, the enhancement in joint performance is dominated by the controlled heat input and the effective Nb-alloying effect, which reduce the thickness and brittleness of the interfacial intermetallic layer, respectively. However, metallurgical regulation of Nb will be restricted by the insufficient Nb melting amount resulting from the low laser power, leading to a decrease in joint properties. Excessive laser power can lead to the formation of hot cracks and an excessive amount of Ti-Al intermetallic compounds, which can decrease the Nb content, thereby restricting the metallurgical regulation of Nb and the overall joint performance.

Process Parameters Influence the Mechanical Properties and Nugget Diameter of AISI 316 Stainless Steel During Resistance Spot Welding

Resistance spot welding (RSW) is an important fusion welding process used in many applications, including storage tanks, pipes, and medical tools. For this, should be improved the joints and developing the process parameters and through this research will be discussed the results and concept development. Herein, 1 mm-thick AISI 316 austenitic stainless steel was welded by RSW, and the effect of the welding process parameters, such as “welding current, pulses, squeeze time, and welding time”, on the mechanical properties, nugget diameter (ND), and microstructure of AISI 316 were investigated. As a result, there was a direct relationship between shear-tensile force and ND. The maximum shear-tensile force (12.5 kN) was obtained using 7500 A, 3 pulses, 1.8 s squeeze time, and 1 s welding time. The ND was maximized using 7500 A, 3 pulses, 1.6 s squeeze time, and 0.8 s welding time. The DOE analysis gives an indication about the relation between the parameters and ND on the hand and the parameters and shear strength on the other hand. The microstructure was investigated by optical microscopy, revealing the presence of martensitic, widmanstatten austenite, and ferrite structures.

Long-term performance of HDPE extrusion welds aged at 85°C in synthetic leachate

The effect of ageing at 85°C of extrusion welds of 1.5 mm-thick high-density polyethylene (HDPE) geomembrane, immersed in synthetic municipal solid waste leachate, is investigated with respect to its standard oxidative induction time (Std-OIT) and stress crack resistance (SCR). Results show that the heat-affected zones (HAZ) adjacent to the squeeze-out bead (flashing) may exhibit faster STD-OIT depletion than the sheet. Generally, individual weld SCR failure times were observed to be between that of the notched and unnotched sheet. Welds with high welding-induced geometric irregularities (WIGI), and overheated fusion and extrusion welds are shown to result in SCR failure times close to that of a notched sheet. The average time to nominal failure (taken to be when tNF = 250 h) of Cool and Good welding parameter combinations ranges between 3% and 15% shorter than the unnotched sheet. Differences in tNF were attributed to accelerated craze formation in welds with high WIGI from stress concentration. No significant difference was observed between the SCR values of fusion and extrusion welds during 40 months of immersion in MSW-L3. This paper shows that overgrind negatively impacts the SCR of welds and accelerates the degradation of SCR.

Characterization of material flow behavior in friction stir welded AA2014 aluminum alloy joints

Abstract Steel rivets serve as a substitute material for connecting similar and dissimilar materials within the structural fabrication industries. However, the use of steel rivets can result in a significant increase in the structure’s weight and may trigger corrosion at the interface due to galvanic coupling. Combining dissimilar alloys through the fusion welding process poses numerous challenges for manufacturers and designers. A solid-state welding technique called friction stir welding (FSW) has been developed. FSW can effectively join materials without reaching their melting points, relying on severe plastic deformation and recrystallization to form a welded joint. The proper selection of the tool and process parameters is essential for achieving a sound weld. The findings of this study indicate that plastic deformation, material flow, and recrystallization play pivotal roles in the strength of the joint. This implies that FSW represents an ideal joining process for high-strength alloys and serves as a viable alternative to replace permanent joints like rivets.

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

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.