Critical life cycle inventory for aluminum die casting: A lightweight-vehicle manufacturing enabling technology

Liu, Weipeng; Peng, Tao; Kishita, Yusuke; Umeda, Yasushi; Tang, Renzhong; Tang, Wangchujun; Hu, Lei

doi:10.1016/j.apenergy.2021.117814

Cited by 33 publications

(10 citation statements)

References 35 publications

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“…The raw material impacts (an aluminium cast alloy) were retrieved from the Ecoinvent database. The melting energy (850 kWh/ton, natural gas), the yield rate, the release agent quantity and the energy consumption of the casting process and nishing were retrieved from LCI study of Liu et al [24]. The weights of the steel mold and countermold were estimated considering similarity with the injection molding tools.…”

Section: Life Cycle Inventorymentioning

confidence: 99%

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Comparative Life Cycle Assessment of Safety Shoes Toe Caps Manufacturing Processes

Bianchi

Forcellese

Simoncini

et al. 2022

Preprint

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Toe caps are fundamental components of safety footwear used to prevent injuries which can be caused by falling objects. They can be realized by exploiting different materials (metal, composites and plastics) and manufacturing processes (stamping, injection molding, compression molding, etc.). However, they have always to fulfill the stringent requirements of safety regulations. In addition, in order to guarantee an ergonomic use, they must be as light as possible. It is estimated that at least 300 million pairs of safety footwear, with 600 million of toe caps, end up in landfill or are incinerated every year. This huge amount of wastes generates a relevant environmental impact, mainly attributable to toe caps manufacturing. In this context, it is important to develop new solutions which minimize the environmental impacts of toe caps manufacturing. Among others, the reuse of carbon fiber prepreg scraps has been recognized as a valid method to produce effective toe caps. In this paper, a detailed analysis of the environmental impacts associated to toe caps realized with reclaimed prepreg scraps has been conducted exploiting the Life Cycle Assessment methodology. The results have been compared to those obtained by analyzing toe caps realized in steel, aluminum, polycarbonate and glass fiber composite. Results demonstrate that the reclaim process for carbon fiber prepreg scraps can be a valid circular economy model to produce more sustainable toe caps for safety footwear.

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Section: Life Cycle Inventorymentioning

confidence: 99%

“…The die surfaces are sprayed with a release agent before each casting process to prevent the sticking of the aluminium. After the cast part is removed, further processes, such as trimming of the runners and over ow, grinding sharp edges, milling and surface nishing, can be carried out [24,25].…”

Section: Aluminium Die Castingmentioning

confidence: 99%

Comparative Life Cycle Assessment of Safety Shoes Toe Caps Manufacturing Processes

Bianchi

Forcellese

Simoncini

et al. 2022

Preprint

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“…Generally, material and energy balances are forms of data representation used to identify and quantify losses (energy and material) and emissions in production units. For instance, an energy balance reveals how products are transformed into one another, highlights the various relationships among these products, and allows for the visualization of the energy consumption in a defined system [16] . Comparably, green data balance (GDB) provides a holistic flow analysis in ratio forms, input to output.…”

Section: Developing a Green Data Balancementioning

confidence: 99%

Enhancing big data for greentelligence across the production value chain

Agbozo¹,

Tao²,

Cao³

et al. 2022

Green Manuf Open

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The big data concept has been explosive, revealing, and transformative across manufacturing industries as it provides deeper insights into manufacturing operations for decision-making. However, big green data (BGA), a dedicated subset of big data, is not adequately structured for comprehensive sustainability analysis, particularly in smart factories. With our proposed green data balance (GDB), there will be accountability for each input and output composition in a production unit within the production value chain (PVC). Data will be exhaustively and accurately collected in each workshop to help uncover unknown issues in a production value chain while facilitating the development of sustainability metrics or index systems. Additionally, a structured big green data system will fuel “greentelligence”, using intelligent systems and technologies to speed up digitalization toward sustainable manufacturing by measuring, tracking, and minimizing adverse environmental impacts. Lastly, with the support of the cognitive intelligence data analytic system (CIDAS), real-time and near real-time comprehensive sustainability analytics can be performed, leading to Self-X metacognitive adjustments and corrective actions.

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“…Among light materials, which include Mg alloys and carbon fiber-reinforced plastics (CFRPs), the lower cost, better moldability, and higher specific strength of Al alloys make them the most promising material for the Al alloy/steel-based design of multi-material automobiles 1,2) . However, to implement the widespread use of multi-material automobiles, several technical issues need to be addressed, such as the challenges of joining dissimilar materials 3,4) , lack of life cycle assessments of multi-material structures for recycling 5,6) , and galvanic corrosion between dissimilar materials [7][8][9][10][11][12] . The prevention of galvanic corrosion on Al alloys coupled with carbon steels has become one of the main challenges in the development of multi-material designs.…”

Section: Introductionmentioning

confidence: 99%

Role of KMnO<sub>4</sub>–NaF Treatment in Galvanic Corrosion Resistance of AA5083 Coupled to Steel

et al. 2023

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The role of KMnO 4 -NaF conversion treatment in the galvanic corrosion resistance of AA5083 aluminum alloy coupled to AISI 1045 carbon steel in synthetic seawater (diluted 100 times) was investigated. The 10 min-treated AA5083 was observed to reduce the period of high current density during the early stage of coupling and decrease the number of localized corrosion damages on the AA5083. The 10 min conversion treatment significantly reduced the electrode potential of bulk Al 6 (Fe, Mn), and it was concluded that the Al 6 (Fe, Mn) particles on the conversion-treated AA5083 no longer acted as a local cathode at the electrode potential when the AA5083 was in contact with AISI 1045 carbon steel. The decrease in cathodic activity of Al 6 (Fe, Mn) was attributed to the removal of Fe from the surface film of Al 6 (Fe, Mn), addition of Mn by the conversion treatment, and thickening of the film.

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Critical life cycle inventory for aluminum die casting: A lightweight-vehicle manufacturing enabling technology

Cited by 33 publications

References 35 publications

Comparative Life Cycle Assessment of Safety Shoes Toe Caps Manufacturing Processes

Comparative Life Cycle Assessment of Safety Shoes Toe Caps Manufacturing Processes

Enhancing big data for greentelligence across the production value chain

Role of KMnO<sub>4</sub>–NaF Treatment in Galvanic Corrosion Resistance of AA5083 Coupled to Steel

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