Life cycle assessment for milling of Ti- and Ni-based alloy aero engine components

Bergs, Thomas; Grünebaum, Timm; Fricke, Kilian; Barth, Sebastian; Ganser, Philipp

doi:10.1016/j.procir.2021.01.165

Cited by 12 publications

(3 citation statements)

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“…The exergy-based analysis is suggested as a valuable supplement to conventional analysis for getting more accurate results. However, no in-depth assessment of particular engine components was conducted here (Atılgan et al, 2013).…”

Section: Life Cycle Impact Assessment: (Focus Of This Paper)mentioning

confidence: 99%

“…Previous works on Blisk-LCA from our scientific working department focused on very basic preliminary results from small-scale Blisk by Bergs et al (2021) and a collaboration with DTU Copenhagen analysed potential benefits of Ti-Blisk recycling without going into technical detail and in-depth analysis (Rupcic et al , 2022). An in-depth assessment of full-size Blisk manufacturing is the focus of this study.…”

Section: Introductionmentioning

confidence: 99%

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Life cycle analysis results for engine blisk LCA

Fricke,

Bergs,

Ganser

et al. 2024

AEAT

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Purpose The aviation industry has seen consistent growth over the past few decades. To maintain its sustainability and competitiveness, it is important to have a comprehensive understanding of the environmental impacts across the entire life cycle of the industry, including materials, processes and resources; manufacturing and production; lifetime services; reuse; end-of-life; and recycling. One important component of aircraft engines, integral rotors known as Blisks, are made of high-value metallic alloys that require complex and resource-intensive manufacturing processes. The purpose of this paper is to assess the ecological and economical impacts generated through Blisk production and thereby identify significant ‘hot-spots’. Design/methodology/approach This paper focuses on the methodology and approach for conducting a full-scale Blisk life cycle assessment (LCA) based on ISO 14040/44. Unlike previous papers in the European Aerospace Science Network series, which focused on the first two stages of LCA, this publication delves into the “life cycle impact assessment” and “interpretation” stages, providing an overview of the life cycle inventory modeling, impact category selection and presenting preliminary LCA results for the Blisk manufacturing process chain. Findings The result shows that the milled titanium Blisk has a lower CO2 footprint than the milled nickel Blisk, which is less than half of the global warming potential (GWP) of the milled nickel Blisk. A main contributor to GWP arises from raw material production. However, no recycling scenarios were included in the analysis, which will be the topic of further investigations. Originality/value The originality of this work lies in the detailed ecological assessment of the manufacturing for complex engine components and the derivation of hot spots as well as potential improvements in terms of eco-footprint reduction throughout the products cradle-to-gate cycle. The LCA results serve as a basis for future approaches of process chain optimisation, use of “greener” materials and individual process improvements.

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Section: Life Cycle Impact Assessment: (Focus Of This Paper)mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Life cycle analysis results for engine blisk LCA

Fricke,

Bergs,

Ganser

et al. 2024

AEAT

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“…Nickel-based superalloy with nickel as the matrix, adding W, Mo, Ti, Al, Nb, Co and other strengthening elements, has excellent high-temperature thermal strength, creep resistance and high-temperature fatigue strength [ 1 ]. The material is widely applied to fabricate structural components [ 2 ] in the aerospace field of 900~1050 °C temperature, such as aero-engine blades [ 3 , 4 , 5 ], turbine discs [ 6 ], combustors [ 7 ], etc. Its excellent chemical and metallurgical properties are mainly reflected in the nickel base alloy being able to dissolve a variety of alloying elements and maintain good structural stability.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Strain Fatigue Behavior for Inconel 625 with Laser Shock Peening

Sun

Han

et al. 2022

Materials

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With excellent creep resistance, high-temperature thermal strength and high-temperature fatigue strength, Inconel 625 is widely applied to fabricate structural components in the aerospace field, where fatigue life is a key point. Laser shock peening (LSP) is considered to improve the fatigue strength and fatigue crack growth resistance of metal materials. The present work was conducted to investigate the influence of LSP on strain-controlled fatigue behavior of Inconel 625. The surface microstructures of specimens before and after LSP were observed by transmission electron microscope (TEM). The strain-controlled fatigue loading tests with different strain amplitudes ranging from 0.4% to 1.2% were carried out on the specimens, and the topography of fracture appearance was examined by scanning electron microscope (SEM). The investigations showed that the specimens with LSP presented fewer crack initiations, shorter fatigue striations space and smaller dimples or micropores, which account for the enhancement of the fatigue life for the LSP specimens. Furthermore, the plastic deformation, ultra-fine grains, twins and dislocations caused by LSP could prevent crack initiation, crack propagation and ultimate fracture, hence prolonging the fatigue life of the Inconel 625. In addition, it was revealed that the cyclic strain hardening as well as cyclic strain softening remains almost the same to Inconel 625 with or without LSP.

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