An environmental impact comparison between wire + arc additive manufacture and forging for the production of a titanium component

Sword, J.  Iain; Galloway, Alexander; Toumpis, Athanasios

doi:10.1016/j.susmat.2023.e00600

Cited by 6 publications

(10 citation statements)

References 41 publications

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“…These comparisons may involve traditional processes such as machining or casting [9] or other metal AM technologies such as SLM [10]. The second axis of evolution incorporates more environmental elements into comparisons, such as quantifying CO2 emissions in addition to the energy aspect [11], or using methods such as ReCiPe to provide a more comprehensive study of numerous standardized criteria [12,13]. The third axis goes with the previous one by broadening the life cycle considered for environmental analyses.…”

Section: Waam Environmental Impactmentioning

confidence: 99%

The Potential of Additive Manufacturing of Metal Components to Reduce Environmental Impacts

Balidas,

Kerbrat,

Hascoet

2024

Journal of Machine Engineering

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Additive manufacturing (AM) is used in metal part forming for its innovative character but its potential for sustainability is uncertain. The energy and material consumption required for manufacturing are significant. Thus, the research question of this article is: "What are the current uses of AM that present a real potential for reducing environmental impact?". The WAAM (Wire Arc Additive Manufacturing) process appears to be the most energyefficient in comparison to other AM processes. A process parameters study shows that deposition rate has a substantial impact on energy consumption. This parameter represents the amount of material deposited in a unit of time and is directly linked to productivity. It appears that an increase of the deposition rate leads to a reduction in energy consumption. Experiments on WAAM with a high deposition rate permits to create a database of energy and material consumption. This database is then used to identify cases of parts made with WAAM that offer a significant impact reduction compared with conventional manufacturing processes.

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Section: Waam Environmental Impactmentioning

confidence: 99%

The Potential of Additive Manufacturing of Metal Components to Reduce Environmental Impacts

Balidas,

Kerbrat,

Hascoet

2024

Journal of Machine Engineering

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“…One method of reducing the environmental impact of manufacturing complex components is to adopt additive manufacturing (AM) [11]. In contrast to subtractive manufacturing techniques such as milling and turning, AM techniques build up a component incrementally from a feedstock such as a powder or wire [12].…”

Section: Introductionmentioning

confidence: 99%

“…Previous LCAs of engineered products have shown that a significant contributor to the environmental impact is the extraction and primary production of materials [34,36]. In addition, the environmental impact of WAAM has been previously studied, in comparison with other common manufacturing techniques such as forging, casting and machining for a range of materials [11,32,37].…”

Section: Introductionmentioning

confidence: 99%

Analysis of Environmental Impact and Mechanical Properties of Inconel 625 Produced Using Wire Arc Additive Manufacturing

Sword,

Galloway,

Toumpis

2024

Sustainability

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Inconel 625 is a nickel-based superalloy widely used in industries such as energy, space, and defence, due to its strength and corrosion resistance. It is traditionally time- and resource-intensive to machine, leading to increased environmental impact and material waste. Using additive manufacturing (AM) technology enables a reduction in resource consumption during the manufacture of high value components, as material is only deposited where it is required. This study compares the environmental impact of manufacturing an Inconel 625 impeller through machining and wire arc additive manufacturing (WAAM) by employing established life cycle assessment methods. WAAM shows significant advantages, cutting energy consumption threefold and reducing material waste from 85% to 35%. The current work also evaluates the mechanical properties of WAAM-produced components through tensile and axial fatigue testing, in addition to the use of optical and electron microscopy for metallurgical analysis and fractography. This demonstrates yield and ultimate tensile strengths exceeding industrial standards, with comparable or superior fatigue life to other AM methods. The improved fatigue performance extends the service life of components, bolstering sustainability by reducing the need for frequent replacements, thereby lessening associated environmental impacts. These findings underscore the promise of WAAM in enhancing both environmental sustainability and mechanical performance in manufacturing Inconel 625 components.

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“…Its effectiveness can be observed by carrying out a Life-Cycle Assessment (LCA), a method used for analyzing the environmental impact of a product, process, service or other economic activity, throughout its life cycle [30][31][32][33][34][35][36], being an important tool to help decision-making aligned with sustainable practices. It is, therefore, a comprehensive tool for quantifying and interpreting the environmental impacts of a product or service from cradle to grave, that is, from raw material extraction process to its final disposal [37,38].…”

Section: Introductionmentioning

confidence: 99%

Assessment Methodology for Calculating Environmental Indicators in the Production of Metal Parts based on the Wire and Arc Manufacturing Method (WAAM)

Mattos,

Filho,

Guimarães

2023

Preprint

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Life Cycle Assessment (LCA) is a technique developed to measure possible environmental impacts during the manufacture and use of a given product or service. Additive Manufacturing (AM) has proven to be suitable in several industries, especially wire and arc additive manufacturing (WAAM), offering many advantages such as delivery time and reduction in terms of material waste, energy consumption and equivalent CO2 emissions (CO2e). This study aimed to develop a methodology to evaluate environmental indicators during the life cycle assessment, from gate-to-gate, in the production of two low-alloy carbon steel metal parts (flanges) using ER-90 wire and allowed identifying the main stages that most influence environmental indicators. The total energy consumption in the production of flanges 1 and 2 were, respectively, 10,239.0 MJ, 12,754.0 MJ and the total carbon footprint, respectively, 714.1 kgCO2e kg-1 and 749.3 kgCO2e kg-1.

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An environmental impact comparison between wire + arc additive manufacture and forging for the production of a titanium component

Cited by 6 publications

References 41 publications

The Potential of Additive Manufacturing of Metal Components to Reduce Environmental Impacts

The Potential of Additive Manufacturing of Metal Components to Reduce Environmental Impacts

Analysis of Environmental Impact and Mechanical Properties of Inconel 625 Produced Using Wire Arc Additive Manufacturing

Assessment Methodology for Calculating Environmental Indicators in the Production of Metal Parts based on the Wire and Arc Manufacturing Method (WAAM)

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