Life Cycle Assessment of aluminum alloys chips recycling through single and multi-step Friction Stir Consolidation processes

Ingarao, Giuseppe; Amato, Massimiliano; Latif, Abdul; Rosa, Angela Daniela La; Lorenzo, Rosa Di; Fratini, Livan

doi:10.1016/j.jmsy.2023.05.021

Cited by 8 publications

(2 citation statements)

References 32 publications

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“…Several SSR processes, including hot forging, extrusion, high-pressure torsion, and friction stir welding, have demonstrated the ability to produce aluminum chip-based products with high performance [4][5][6]. Utilizing SSR recycling processes to efficiently recycle aluminum chip waste into functional parts reduces material waste and energy consumption compared to the remelting method [5,7,8].…”

Section: Introductionmentioning

confidence: 99%

Optimizing strength of directly recycled aluminum chip-based parts through a hybrid RSM-GA-ANN approach in sustainable hot forging

Altharan,

Shamsudin,

Lajis

et al. 2024

PLoS ONE

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Direct recycling of aluminum waste is crucial in sustainable manufacturing to mitigate environmental impact and conserve resources. This work was carried out to study the application of hot press forging (HPF) in recycling AA6061 aluminum chip waste, aiming to optimize operating factors using Response Surface Methodology (RSM), Artificial Neural Network (ANN) and Genetic algorithm (GA) strategy to maximize the strength of recycled parts. The experimental runs were designed using Full factorial and RSM via Minitab 21 software. RSM-ANN models were employed to examine the effect of factors and their interactions on response and to predict output, while GA-RSM and GA-ANN were used for optimization. The chips of different morphology were cold compressed into billet form and then hot forged. The effect of varying forging temperature (Tp, 450–550°C), holding time (HT, 60–120 minutes), and chip surface area to volume ratio (AS:V, 15.4–52.6 mm2/mm3) on ultimate tensile strength (UTS) was examined. Maximum UTS (237.4 MPa) was achieved at 550°C, 120 minutes and 15.4 mm2/mm3 of chip’s AS: V. The Tp had the largest contributing effect ratio on the UTS, followed by HT and AS:V according to ANOVA analysis. The proposed optimization process suggested 550°C, 60 minutes, and 15.4 mm2 as the optimal condition yielding the maximum UTS. The developed models’ evaluation results showed that ANN (with MSE = 1.48%) outperformed RSM model. Overall, the study promotes sustainable production by demonstrating the potential of integrating RSM and ML to optimize complex manufacturing processes and improve product quality.

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Section: Introductionmentioning

confidence: 99%

Optimizing strength of directly recycled aluminum chip-based parts through a hybrid RSM-GA-ANN approach in sustainable hot forging

Altharan,

Shamsudin,

Lajis

et al. 2024

PLoS ONE

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“…Only a few articles exist in the literature that focus on the environmental impact of processes, such as ECAP, FSE, and FSC. These studies mainly related to the extrusion or forging processes for the production billets, wires, and disks [16][17][18][19]. There is a noticeable lack of knowledge and research when it comes to solid state recycling for producing sheets for metal forming.…”

Section: Introductionmentioning

confidence: 99%

Sustainability Study of a New Solid-State Aluminum Chips Recycling Process: A Life Cycle Assessment Approach

et al. 2023

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Nowadays, reducing greenhouse gas emissions in all human activities has become crucial. This article presents a life cycle assessment (LCA) investigation conducted to evaluate the environmental benefits of a newly developed solid-state recycling process for aluminum chips, involving two steps: direct rolling and accumulative roll bonding. A comparison was made between this process and two current industrial methods of recycling aluminum scraps to obtain wrought products, which involve melting, casting, and subsequent rolling. The LCA analysis considered a scenario where 50% of the total electric requirement was met by photovoltaic energy. The results of the study indicate that in all examined impact categories, direct rolling has a lower environmental footprint compared to both traditional recycling and twin-roll cast technology. These results suggest that this new solid-state recycling procedure has significant potential to replace environmentally harmful melting processes.

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A review of principles and options for the re-use of machining chips by solid, semi-solid or melt-based processing

Murray,

Jin,

Cleaver

et al. 2024

Journal of Materials Processing Technology

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Life Cycle Assessment of aluminum alloys chips recycling through single and multi-step Friction Stir Consolidation processes

Cited by 8 publications

References 32 publications

Optimizing strength of directly recycled aluminum chip-based parts through a hybrid RSM-GA-ANN approach in sustainable hot forging

Optimizing strength of directly recycled aluminum chip-based parts through a hybrid RSM-GA-ANN approach in sustainable hot forging

Sustainability Study of a New Solid-State Aluminum Chips Recycling Process: A Life Cycle Assessment Approach

A review of principles and options for the re-use of machining chips by solid, semi-solid or melt-based processing

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