Metal Casting Energy Efficient Metrics for Material Selection of Automotive Parts

Pagone, Emanuele; Papanikolaou, Michail; Salonitis, Konstantinos; Jolly, Mark

doi:10.1007/978-3-030-04290-5_29

Cited by 5 publications

(6 citation statements)

References 24 publications

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“…It is interesting to note that the only exception to this observation is the manufacturing energy efficiency of the plant where ZA-8 is the worst option, showing that there is an opportunity to further improve the performance of ZA-8 foundries, pushing them to approach their theoretical minimum energy consumption. This hypothesis has been verified in a previous study which suggests that the melting process of ZA-8, in particular, can be improved with a great potential benefit for the overall foundry energy performance (Pagone, Papanikolaou, et al, 2018).…”

Section: Ranking Of the Alternative Solutions By The Descending Valuesupporting

confidence: 67%

“…However, it does not take into consideration its performance in comparison to the ideal case for the specific alloy being processed. Thus, a measure of the manufacturing energy efficiency has been proposed (Pagone, Papanikolaou, et al, 2018;:…”

Section: Environmental Sustainabilitymentioning

confidence: 99%

“…The manufacturing energy efficiency has been taken from a previous publication of the authors (Pagone, Papanikolaou, et al, 2018). (Eppich, 2004) 0.52 (Eppich, 2004) Die life in number of cycles (Schrader and Elshennawy, 2000) cycles 0.24 10 5 10 5 10 6…”

Section: Ranking Of the Alternative Solutions By The Descending Valuementioning

confidence: 99%

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Multi-criteria decision-making for the life cycle of sustainable high pressure die casting products

Pagone¹,

Papanikolaou²,

Salonitis³

et al. 2020

IJSM

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Although a significant body of literature has been devoted to establish metrics capable of measuring the performance of manufacturing systems (including foundries) and their influence on decision-making, there is a scarcity of comprehensive and organic studies on performance indicators encompassing sustainability. The objective of this investigation is the selection of the most suitable material for the manufacture of an automotive component using the High Pressure Die Casting (HPDC) process. The performance of three different alloys (Aluminium-A380, Magnesium-AZ91D and Zinc-ZA8) was evaluated based on four different classes of metrics, namely: (a) cost, (b) time, (c) quality and (d) sustainability. The metrics selected refer to the overall product life cycle and process characteristics and have been normalised by mass to extend the applicability of the selection method to parts produced with similar process and design specifications but different mass. The deterministic TOPSIS method has been adopted to weigh and combine the different metrics used and drive the decision making process. According to the results, although the zinc alloy appears to be the most expensive option, it should be favoured over the two alternatives due to its significantly superior performance with respect to the quality and sustainability criteria. The current investigation demonstrates that the implementation of the TOPSIS method in combination with the added sustainability dimension influences the decision making process and challenges well-established decision making trends in the automotive industry during the past few decades.

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Section: Ranking Of the Alternative Solutions By The Descending Valuesupporting

confidence: 67%

Section: Environmental Sustainabilitymentioning

confidence: 99%

See 1 more Smart Citation

Multi-criteria decision-making for the life cycle of sustainable high pressure die casting products

Pagone¹,

Papanikolaou²,

Salonitis³

et al. 2020

IJSM

Self Cite

View full text Add to dashboard Cite

show abstract

“…Metal casting is one of the most energy-intensive manufacturing processes [113], especially in the iron and steel division. In 2013, the iron and steel sector recorded 18% of the total energy consumption of all industry worldwide [114,115].…”

Section: Metal Casting Industrymentioning

confidence: 99%

Energy Efficiency and Industry 4.0 in Wood Industry: A Review and Comparison to Other Industries

Haddouche

Ilinca

2022

Energies

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This paper presents a literature review of recent research on introducing the Industry 4.0 approach to improving energy efficiency, especially in the wood industry. While researchers focus on processes, service, and customer concepts, the effect on energy consumption is less addressed in these studies and applications. This paper focuses on previous works that discuss how to apply Industry 4.0 concepts to energy issues, such as to achieve better efficiency and performance for the industry in general and the wood industry in particular. The complexity of the study requires a multistep development. First, we define each concept separately and the relationships between them. Second, we apply a search algorithm to find related articles with specific terms, and then use the PRISMA method to select the most important ones, eliminating duplicates and excluding articles that do not mention energy efficiency and Industry 4.0 in the manufacturing or wood industry. Third, we explain and categorize the results and consolidate the study with brief examples from other industries. Finally, we conclude the study by mentioning the limitations and perspectives.

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“…The new set of metrics has been proven particularly useful comparing real-world data related to a product manufactured from different alloys (i.e. Aluminium, Magnesium and Zinc-based alloys) using the same High-Pressure Die Casting (HPDC) process [5]. In this case, SECo showed very similar values for the Aluminium and Zinc alloy foundries, whereas (that takes into account the thermodynamic characteristic of the specific alloy) uncovered the potential to improve further the Zinc-based process, and identified in the melting and holding phases the opportunity for improvement [6].…”

Section: Metrics and Energy Auditing Frameworkmentioning

confidence: 99%

Energy Resilient Foundries: The “Small is Beautiful” Projects

et al. 2022

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Applying the concept of "small is beautiful" into a conservative relatively low technology manufacturing sector where the "economies of scale" argument has been used to build ever more so-called efficient process lines is a major challenge. The energy efficiency of the casting process has only been investigated in a limited fashion. The two "Small is Beautiful" projects aimed to introduce a new concept into foundries with regards the use of their resources. The new philosophy, "small is beautiful", starts by encouraging the use of high-quality feedstock, only melting what is required and only when it is required. Recycling of internal scrap is not necessarily acceptable but an aim for higher yields is. Applying counter gravity casting methods to improve yield and give enhanced quality is encouraged as is the recovery of lowgrade heat from solidification. The present paper discusses the research undertaken and the key findings from the two projects.

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Metal Casting Energy Efficient Metrics for Material Selection of Automotive Parts

Cited by 5 publications

References 24 publications

Multi-criteria decision-making for the life cycle of sustainable high pressure die casting products

Multi-criteria decision-making for the life cycle of sustainable high pressure die casting products

Energy Efficiency and Industry 4.0 in Wood Industry: A Review and Comparison to Other Industries

Energy Resilient Foundries: The “Small is Beautiful” Projects

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