Surface integrity of the machined surface is an important aspect considering their surface alterations, metallurgical effects, and mechanical characteristics during the machining process. Industries have been seeking a capable machining technology that can improve the machining process capabilities especially in an eco-friendly manner. Hybrid machining processes have shown significant improvement in machining performance when compared with the conventional turning (CT) process without using any cutting fluids. Moreover, a recently developed hybrid machining technology, that is, ultrasonic-vibration-laser assisted turning (UVLAT) has shown better machinability than the CT process. Therefore, an attempt has been made to improve the surface integrity of aluminum 3003 alloy in terms of machining forces, surface roughness, surface damage, microstructure, microhardness, residual stresses, and corrosion behavior during the UVLAT process. A comparative surface integrity analysis has been performed among the CT, ultrasonic vibration assisted turning (UVAT), laser assisted turning (LAT), and UVLAT processes. Significant improvement in the surface integrity has been observed for the aluminum 3003 alloy during the UVLAT process in comparison to the CT, UVAT, and LAT processes. The periodic separation of the cutting tool and thermal softening of the workpiece material, simultaneously during the UVLAT process is the possible reason for the improvement in surface integrity. Results demonstrated that the UVLAT process has an excellent potential to enhance the surface integrity of aluminum alloys and is better than the CT, UVAT, and LAT processes.
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