Remanufacturing of turbine blades by laser direct deposition with its energy and environmental impact analysis

Wilson, J. Michael; Piya, Cecil; Shin, Yung C.; Zhao, Fu; Ramani, Karthik

doi:10.1016/j.jclepro.2014.05.084

Cited by 386 publications

(138 citation statements)

References 22 publications

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“…For 1 kg of metallic glass powder, the consumption rates were quantified to 7 m³ of argon, 14.4 MJ of electricity, and 155 liters of water. Wilson and colleagues () reported an SEC of 55.6 MJ/kg for the atomization of a nickel‐based super alloy (Nistelle 625 from Deloro Stellite®).…”

Section: Environmental Analysis Of Additive Manufacturing Technologiesmentioning

confidence: 99%

“…Turbine blades are well known as an example of RM using AM. Jones and colleagues () and Wilson and colleagues () described the remanufacturing of such turbine blades by laser cladding and laser direct deposition (LDD) processes, respectively. While the first study mainly focused on technological issues, the latter includes an energy and environmental impact analysis.…”

Section: Potential Life Cycle Benefits Of Additive Manufacturing Manumentioning

confidence: 99%

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Environmental Dimensions of Additive Manufacturing: Mapping Application Domains and Their Environmental Implications

Kellens

Baumers

Gutowski

et al. 2017

J of Industrial Ecology

208

128

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SummaryAdditive manufacturing (AM) proposes a novel paradigm for engineering design and manufacturing, which has profound economic, environmental, and security implications. The design freedom offered by this category of manufacturing processes and its ability to locally print almost each designable object will have important repercussions across society. While AM applications are progressing from rapid prototyping to the production of end-use products, the environmental dimensions and related impacts of these evolving manufacturing processes have yet to be extensively examined. Only limited quantitative data are available on how AM manufactured products compare to conventionally manufactured ones in terms of energy and material consumption, transportation costs, pollution and waste, health and safety issues, as well as other environmental impacts over their full lifetime. Reported research indicates that the specific energy of current AM systems is 1 to 2 orders of magnitude higher compared to that of conventional manufacturing processes. However, only part of the AM process taxonomy is yet documented in terms of its environmental performance, and most life cycle inventory (LCI) efforts mainly focus on energy consumption. From an environmental perspective, AM manufactured parts can be beneficial for very small batches, or in cases where AM-based redesigns offer substantial functional advantages during the product use phase (e.g., lightweight part designs and part remanufacturing). Important pending research questions include the LCI of AM feedstock production, supply-chain consequences, and health and safety issues relating to AM.

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Section: Environmental Analysis Of Additive Manufacturing Technologiesmentioning

confidence: 99%

Section: Potential Life Cycle Benefits Of Additive Manufacturing Manumentioning

confidence: 99%

Environmental Dimensions of Additive Manufacturing: Mapping Application Domains and Their Environmental Implications

Kellens

Baumers

Gutowski

et al. 2017

J of Industrial Ecology

208

128

View full text Add to dashboard Cite

show abstract

“…At present, AM is also applied to impeller production (Calleja et al 2014;Fernández et al 2015). Impeller RM has received extensive attention as well (Bi and Gasser 2011;Wilson et al 2014). As defined by the American Society for Testing and Materials, AM is "a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies" (Frazier 2014(Frazier , p. 1917.…”

Section: Introductionmentioning

confidence: 99%

Toward a Sustainable Impeller Production: Environmental Impact Comparison of Different Impeller Manufacturing Methods

Peng

Wang

et al. 2017

J of Industrial Ecology

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SummaryImpellers are the core components of turbomachinery in petrochemical and aeronautical engineering. In addition to conventional manufacturing (CM), additive manufacturing (AM) and remanufacturing (RM) can also be used in impeller production. This article presents a life cycle assessment method comparing the environmental impacts of different impeller manufacturing methods, including plunge milling (CM), laser cladding forming (AM combined with CM), and additive remanufacturing (RM). Results show that RM is the most environmentally favorable option, followed by AM and CM, in terms of global warming potential (GWP), Chinese resource depletion potential (CADP), water eutrophication potential (EP), and acidification potential. However, AM is not always more environmentally friendly than CM. The comparison of impeller production by CM and pure AM, in this case, indicates that the environmental burden of production using pure AM is approximately twice than that of CM. Compared with CM, the RM of impellers would reduce GWP, CADP, and EP by 64.7%, 66.1%, and 75.4%, respectively. The results of this study contribute to a scientific basis for the selection of manufacturing methods and the sustainable manufacturing of impeller production enterprises.

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“…AM technology is also suitable for the reparation of aircraft engine parts, such as turbine blades, as well as suitable for the production of complex parts for end-use applications [19]. However, AM-produced or repaired components will still require post-processing, which is mostly performed by NC machining of the remanufactured part [20].…”

Section: Introductionmentioning

confidence: 99%

The ultrasonic burnishing of cobalt-chrome and stainless steel surface made by additive manufacturing

2017

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post-processing of 316L requires 1000 mm/min for the feed speed, 0.025 mm for the side shift and 1 mm for spring compression, when taking also productivity into consideration. The results of this experiment show that the subtractive methods and labour-intensive post-processing of AM metal parts can be replaced by burnishing methods, thus reducing the cost barriers of additive technology and drive its adoption in industry.

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Remanufacturing of turbine blades by laser direct deposition with its energy and environmental impact analysis

Cited by 386 publications

References 22 publications

Environmental Dimensions of Additive Manufacturing: Mapping Application Domains and Their Environmental Implications

Environmental Dimensions of Additive Manufacturing: Mapping Application Domains and Their Environmental Implications

Toward a Sustainable Impeller Production: Environmental Impact Comparison of Different Impeller Manufacturing Methods

The ultrasonic burnishing of cobalt-chrome and stainless steel surface made by additive manufacturing

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