Investigation of Energy Requirements and Environmental Performance for Additive Manufacturing Processes

Liu, Zhichao; Jiang, Qiuhong; Ning, Fuda; Kim, Hoyeol; Cong, Weilong; Xu, Changxue; Zhang, Hongchao

doi:10.3390/su10103606

Cited by 43 publications

(18 citation statements)

References 27 publications

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“…In the repairing scenario, the amount of argon and powder consumed by the DED can cause significant increase to the operation and maintenance costs. The electricity consumed has more significance in the LCA study, mostly due to the contribution of natural gas to the Portuguese electricity mix, in agreement with recent literature [20,56].…”

Section: Discussionsupporting

confidence: 89%

Life Cycle Assessment and Cost Analysis of Additive Manufacturing Repair Processes in the Mold Industry

et al. 2022

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There is a growing demand for data regarding the environmental and economic performance of additive manufacturing to establish the role of this technology in the future circular industrial economy. This paper provides a comparative analysis of direct energy deposition technology with conventional manufacturing, specifically iron casting, in the context of the repairing capabilities of the direct energy deposition system in a damaged glass bottle mold. Making use of already established methodologies for environmental and economic assessment, a life cycle assessment and a life cycle costing study was conducted on each scenario to provide a holistic perspective on the advantages and limitations of each system. With the gathered life cycle inventory, the main environmental impacts and life cycle costs were determined. The hybrid repairing scenario results show a reduction of the environmental impacts and life cycle costs by avoiding resource consumption in the production of a new mold, with underlying economic advantages identified beyond the calculated results. Through strategic integration based in life cycle approaches, it is concluded that direct energy deposition technology can play a key role in the sustainable development of tooling and manufacturing industries, especially in products with large dimensions, complex geometry, and customized design.

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Section: Discussionsupporting

confidence: 89%

Life Cycle Assessment and Cost Analysis of Additive Manufacturing Repair Processes in the Mold Industry

et al. 2022

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“…Additional benefits of LPBF involve lower energy consumption 27,28 and higher powder recyclability 29 when compared with the DED/LENS processes. Typically, DED/LENS employs high power heating source (electrons/ laser) in the kilowatts power range, whereas LPBF uses lasers in the range of few hundred watts 11,19,30 .…”

mentioning

confidence: 99%

Metallurgical and Electrochemical Properties of Super Duplex Stainless Steel Clads on Low Carbon Steel Substrate produced with Laser Powder Bed Fusion

Murkute

Pasebani

Isgor

2020

Sci Rep

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this study aims to improve the corrosion resistance of the low carbon steel by cladding it with super duplex stainless steel using laser powder bed fusion process. critical process parameters such as laser power, laser scan speed, hatch spacing, and powder layer thickness were optimized to achieve the best possible metallurgical bonding between the clad and the substrate. the evaporative losses experienced during the laser melting process resulted in clad layers with lower chromium content (12-25 wt. %) as compared to 26 wt. % of the feedstock powder. A clad thickness of 65.8 µm was achieved after melting ten 50 µm thick powder layers. the higher cooling rates associated with laser powder bed fusion resulted in fine high aspect ratio columnar grain structures with predominantly ferrite grains; however, widmanstätten austenite needles were observed with increasing laser scan speeds. increasing scan speed had a negative impact on the thickness, corrosion resistance, and the pitting potential of the clads exposed to 3.5 wt.% NaCl aqueous solution. Clads produced at the lowest scan speeds showed comparable corrosion resistance to rolled and annealed super duplex stainless steel. Duplex stainless steels (DSS) are a special class of ferrous alloys with a balanced ferrite (δ) and austenite (γ) phase microstructure. This dual-phase structure imparts these steels a high strength, toughness, and increased corrosion resistance in environments containing acids, acid chlorides, seawater, and caustic chemicals. Super duplex stainless steels (SDSS) 1 are a variant of DSS with higher Cr (25-26 wt. %) and Mo (4 wt. %) contents. SDSS typically shows superior pitting and stress corrosion cracking resistance than DSS; therefore, the use of SDSS has been increasing in highly corrosive environments, including oil and gas infrastructure, desalination plants, chemical storage tanks, heat exchangers, and paper/pulp manufacturing facilities 1. Although low carbon steel (LCS) remains to be the most widely used ferrous alloy, its applications are limited because it is highly vulnerable to corrosion in neutral, acidic, or saline environments 2. Corrosion-resistant SDSS alloys possess superior corrosion resistance than the LCS for the aforementioned applications, albeit with a significantly higher material cost. One of the viable means to reduce the component cost without compromising on service life is to manufacture a composite with a low-cost tough and ductile substrate cladded with a wear and corrosion resistant surface, as in the case of SDSS clads on an LCS substrate. These dissimilar metal composites (cladded systems) have been produced in the past using conventional manufacturing techniques such as welding 3-5 , diffusion bonding 6 , powder roll bonding 7 , hot rolling 8 , and reduction bonding 9. However, conventionally manufactured composites are often unfit for field use due to substandard clad-substrate bonding, often leading to clad delamination when subjected to operational stresses in the field. This substandard bond typically ...

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“…The promising application of zirconium (Zr) is related to titanium-based alloys. Binary and ternary Ti-based alloys with zirconium, niobium, and tantalum are regarded as the most promising substitution of Ti64 for biomedical applications [ 84 ], showing significantly better biocompatibility and having mechanical properties much closer to those of human bones [ 16 , 17 , 85 , 86 , 87 , 88 ]. Growing demand for prostheses and implants and the ability of additive manufacturing to functionalize them will determine the demand for Zr as an alloying element rather than an individual material.…”

Section: Powder Materials Used For Additive Manufacturingmentioning

confidence: 99%

“…AM adds a material layer-by-layer, in contrast to the traditional methods of subtractive manufacturing that remove material from large ingots by turning, drilling, and milling. Unique advantages of AM methods include achieving unprecedented freedom in the shape, significant reduction of waste, and, in many cases, reduction of energy consumption [ 15 , 16 , 17 ]. Specific processing conditions characteristic of AM allow for developing new materials with unique properties not possible to manufacture by other methods, including bulk metallic glasses [ 18 , 19 ], high-entropy alloys [ 20 , 21 , 22 ], and different composites [ 23 , 24 ].…”

Section: Introductionmentioning

confidence: 99%

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

et al. 2021

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The term “critical raw materials” (CRMs) refers to various metals and nonmetals that are crucial to Europe’s economic progress. Modern technologies enabling effective use and recyclability of CRMs are in critical demand for the EU industries. The use of CRMs, especially in the fields of biomedicine, aerospace, electric vehicles, and energy applications, is almost irreplaceable. Additive manufacturing (also referred to as 3D printing) is one of the key enabling technologies in the field of manufacturing which underpins the Fourth Industrial Revolution. 3D printing not only suppresses waste but also provides an efficient buy-to-fly ratio and possesses the potential to entirely change supply and distribution chains, significantly reducing costs and revolutionizing all logistics. This review provides comprehensive new insights into CRM-containing materials processed by modern additive manufacturing techniques and outlines the potential for increasing the efficiency of CRMs utilization and reducing the dependence on CRMs through wider industrial incorporation of AM and specifics of powder bed AM methods making them prime candidates for such developments.

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Investigation of Energy Requirements and Environmental Performance for Additive Manufacturing Processes

Cited by 43 publications

References 27 publications

Life Cycle Assessment and Cost Analysis of Additive Manufacturing Repair Processes in the Mold Industry

Life Cycle Assessment and Cost Analysis of Additive Manufacturing Repair Processes in the Mold Industry

Metallurgical and Electrochemical Properties of Super Duplex Stainless Steel Clads on Low Carbon Steel Substrate produced with Laser Powder Bed Fusion

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

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