A comparative assessment of energy demand and life cycle costs for additive- and subtractive-based manufacturing approaches

Ingarao, Giuseppe; Priarone, Paolo Claudio

doi:10.1016/j.jmapro.2020.06.009

Cited by 60 publications

(26 citation statements)

References 49 publications

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“…However, R&D activities are continuously focused on developing new materials for AM, so the variety is constantly increasing. Optimal usage and exploitation of materials with lower production scraps are the potential benefits of AM [98]. Better process reliability and operator knowledge are the challenges for future improvements within the sustainability framework.…”

Section: E62 Processes For Metals: Am Processes For Metals Include mentioning

confidence: 99%

Mapping Industry 4.0 Enabling Technologies into United Nations Sustainability Development Goals

et al. 2021

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The emerging of the fourth industrial revolution, also known as Industry 4.0 (I4.0), from the advancement in several technologies is viewed not only to promote economic growth, but also to enable a greener future. The 2030 Agenda of the United Nations for sustainable development sets out clear goals for the industry to foster the economy, while preserving social well-being and ecological validity. However, the influence of I4.0 technologies on the achievement of the Sustainable Development Goals (SDG) has not been conclusively or systematically investigated. By understanding the link between the I4.0 technologies and the SDGs, researchers can better support policymakers to consider the technological advancement in updating and harmonizing policies and strategies in different sectors (i.e., education, industry, and governmental) with the SDGs. To address this gap, academic experts in this paper have investigated the influence of I4.0 technologies on the sustainability targets identified by the UN. Key I4.0 element technologies have been classified to enable a quantitative mapping with the 17 SDGs. The results indicate that the majority of the I4.0 technologies can contribute positively to achieving the UN agenda. It was also found that the effects of the technologies on individual goals varies between direct and strong, and indirect and weak influences. The main insights and lessons learned from the mapping are provided to support future policy.

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Section: E62 Processes For Metals: Am Processes For Metals Include mentioning

confidence: 99%

Mapping Industry 4.0 Enabling Technologies into United Nations Sustainability Development Goals

et al. 2021

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“…A primary-tosecondary energy conversion efficiency of 0.38 was Fig. 5 Form defect of the holes in the ID 6 sample (nominal geometry indicated with a red-dashed line) considered [33]. Moreover, unless otherwise specified, a ± 10% range of variation was assumed for the input data collected from the literature to consider data uncertainty [30].…”

Section: Cumulative Energy Demandmentioning

confidence: 99%

“…The purchase costs of the incoming feedstock material (i.e., the metal powder for the EBM machine) was quantified as 175 € per kg of Ti-6Al-4V powder, according to Ingarao and Priarone [33]. This cost, which is driven by market rules, was assumed to vary within a ± 10% range, in order to account for market fluctuations.…”

Section: Direct Materials Costsmentioning

confidence: 99%

“…The utilization times for the sandblaster and the WEDM machine were estimated by assuming a working time of two or three 8-h shifts per day, over 220 working days per year. The cost of electricity was 0.15 ± 10% €/kWh, whereas a total specific cost of 10.9 ± 10% €/kg was considered for the HIP of Ti-6Al-4V (according to Ingarao and Priarone [33], who referred to the data of Laureijs et al [39]).…”

Section: Manufacturing Overhead Costsmentioning

confidence: 99%

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The technology, economy, and environmental sustainability of isotropic superfinishing applied to electron-beam melted Ti-6Al-4V components

Atzeni

Catalano

Priarone

et al. 2021

Int J Adv Manuf Technol

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Additive manufacturing (AM) processes allow complex geometries to be produced with enhanced functionality, but technological challenges still have to be dealt with, in terms of surface finish and achieved tolerances. Among the consolidated powder-bed fusion processes, electron beam melting (EBM), which allows almost stress-free parts to be manufactured with a high productivity and minimum use of support structures, suffers from a poor surface quality. Thus, finishing processes have to be performed. The same geometrical complexity, which is considered one of the benefits of AM, becomes an issue when finishing is applied, in particular when internal features are present. Unconventional isotropic superfinishing processes could be a solution to this problem since they can generate a low surface roughness on complex geometries. However, the performance characteristics, with regard to the environmental sustainability and economic aspects, need to be evaluated since they are key factors that must be considered for decision-support tools when selecting a finishing process. The technological feasibility of the isotropic superfinishing (ISF) process, applied to Ti-6Al-4V parts produced by electron beam melting, is investigated in this paper by considering the dimensional and geometrical deviations induced by the finishing treatment, and from observations of the surface morphology. A significant reduction in surface roughness, Sa, to around 4 μm, has been observed on the most irregular surfaces, although the original shape is maintained. Environmental sustainability has been analyzed for all the manufacturing steps, from powder production to part fabrication, to the finishing process, and both the cumulative energy demand and material waste have been accounted for. The economic impact of the whole manufacturing chain has been evaluated, and the advantages of the ISF process are pointed out.

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“…Wire arc additive manufacturing Le, Paris [7] Cradle to gate Lightweight part Ti-6Al-4V Machining EBM Priarone et al [18] Cradle to grave Mechanical part Ti-6Al-4V CNC lathe EBM Ingarao, Priarone [26] Cradle to grave Mechanical part Ti-6Al-4V Turning EBM…”

Section: Hot Rolling and Machiningmentioning

confidence: 99%

Environmental impacts of conventional and additive manufacturing for the production of Ti-6Al-4V knee implant: a life cycle approach

Lyons

Newell

Ghadimi

et al. 2020

Int J Adv Manuf Technol

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This paper explores whether additive manufacturing (AM) is more environmentally friendly than conventional manufacturing (CM) for the production of medical implants. The environmental impact of manufacturing the femoral component of a knee implant made from Ti-6Al-4V material was investigated. One AM method (electron beam melting (EBM)) and one CM method (milling) were analysed for the production of this part. A cradle to grave life cycle approach was utilised for each manufacturing method focusing on the primary energy consumption (PEC) and CO2 emissions. It was found that when the entire life cycle of the implant is considered, EBM is a more environmentally friendly method of producing the implant. This is mainly due to the complex geometry of the implant. For complex geometries, lots of waste material is generated using CM processes, whereas much less material is wasted using the AM process. The production of the raw material, Ti-6Al-4V, has a high PEC and associated CO2 emissions, so the amount of required raw material for either manufacturing method is the most important factor from an environmental perspective. Finally, the article presents the plans for future work and some remarks are concluded.

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A comparative assessment of energy demand and life cycle costs for additive- and subtractive-based manufacturing approaches

Cited by 60 publications

References 49 publications

Mapping Industry 4.0 Enabling Technologies into United Nations Sustainability Development Goals

Mapping Industry 4.0 Enabling Technologies into United Nations Sustainability Development Goals

The technology, economy, and environmental sustainability of isotropic superfinishing applied to electron-beam melted Ti-6Al-4V components

Environmental impacts of conventional and additive manufacturing for the production of Ti-6Al-4V knee implant: a life cycle approach

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