A　new　multi-physics　field　mathematical　model　is　established　to　describe　an　advanced　current-induced　friction　stir　welding　(CFSW)　process.　A　reverse　method　and　large-batch　parameter　scanning　technique　are　used　to　analyze　the　influence　of　the　axial　force,　welding　rotational　speed　ratio,　and　current　on　the　temperature　field,　flow　field,　residual　strain,　and　stress　field　of　CFSW.　The　thermal-force　comprehensive　effect　of　the　additional　current　is　studied　in　CFSW.　The　research　results　show　that　the　hybrid　current　can　achieve　effective　metallurgical　bonding　as　a　new　current-induced　friction　stir　welding　mode,　when　the　effective　welding　joint　cannot　be　obtained　due　to　insufficient　heat　input　in　traditional　FSW.　The　high-temperature　zone　area　of　CFSW　is　larger　than　that　of　conventional　FSW,　and　the　hybrid　current　is　helpful　to　reduce　residual　stress　and　strain.　The　additional　current　can　increase　the　flow　velocity　of　metal　in　welding　seam,　but　it　has　little　influence　on　the　flow　path　and　pattern　of　welding　seam　metal.　More　importantly,　CFSW　process　allows　higher　welding　speed　and　lower　axial　force　owing　to　auxiliary　resistance　heat　compared　with　traditional　FSW,　which　makes　CFSW　able　to　achieve　higher　production　efficiency　and　save　tool　cost.　The　three-dimensional　multi-physics　field　mathematical　model　of　CFSW　is　reliable　and　correct　in　this　paper.　©　2020,　Springer-Verlag　London　Ltd.,　part　of　Springer　Nature.