Publicação
Integrating Life Cycle Sustainability in Wire Arc Additive Manufacturing for Sustainable Metal Parts Production
| Resumo: | Climate change, driven by toxic emissions and rising temperatures, is a major concern, with the manufacturing sector being a significant contributor. However, manufacturing is vital for the economy and living standards. Reducing emissions and adverse social impacts while maintaining cost competitiveness through sustainable practices is crucial. Traditional subtractive manufactur- ing processes like Computer Numeric Control (CNC) machining, despite achieving high precision and smooth finishes, generate substantial material waste, limiting their sustainability. Metal Ad- ditive Manufacturing (MAM), particularly Powder Bed Fusion (LPBF), offers significant opportu- nities for improving material efficiency but suffers from slow build rates and low energy effi- ciency, limiting its environmental benefits and widespread adoption due to high costs and re- quired post-processing. Conversely, Wire Arc Additive Manufacturing (WAAM), an emerging Di- rected Energy Deposition (DED) technology, offers higher build rates suitable for large parts with more affordable machine tools. However, WAAM parts often require additional machining and heat treatments due to issues like high residual stresses and poor surface finish, impacting its sustainability. Considering these opportunities and challenges, it is essential to ensure WAAM's sustainable development through Life Cycle Sustainability Assessment (LCSA) that encompasses its environmental, economic, and social dimensions. This PhD work aims to comprehensively as- sess WAAM's performance in terms of environmental impact, manufacturing costs, and social impacts, focusing on industrial applications. Using Life Cycle Assessment (LCA), Life Cycle Costing (LCC), and Social Life Cycle Assessment (S-LCA) methodologies, environmental impacts, costs and social impacts of WAAM are evaluated. Additionally, the mechanical properties imparted by WAAM parts are characterized and compared with LPBF and CNC machining. Furthermore, an online LCSA tool enabling designers and engineers to compare the sustainability of WAAM, and traditional CNC machining approaches is developed, facilitating the selection of the most sus- tainable manufacturing processes. The insights gained will be helpful for decision-makers in re- ducing the environmental footprint, optimizing costs, mitigating adverse social impacts, thereby promoting sustainability from the eary stages of product 's life cycle. |
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| Autores principais: | Kokare, Samruddha |
| Assunto: | Wire Arc Additive Manufacturing Life Cycle Sustainability Assessment Life Cycle Assessment Life Cycle Costing Social Life Cycle Assessment Sustainability |
| Ano: | 2024 |
| País: | Portugal |
| Tipo de documento: | tese de doutoramento |
| Tipo de acesso: | acesso aberto |
| Instituição associada: | Universidade Nova de Lisboa |
| Idioma: | inglês |
| Origem: | Repositório Institucional da UNL |
| Resumo: | Climate change, driven by toxic emissions and rising temperatures, is a major concern, with the manufacturing sector being a significant contributor. However, manufacturing is vital for the economy and living standards. Reducing emissions and adverse social impacts while maintaining cost competitiveness through sustainable practices is crucial. Traditional subtractive manufactur- ing processes like Computer Numeric Control (CNC) machining, despite achieving high precision and smooth finishes, generate substantial material waste, limiting their sustainability. Metal Ad- ditive Manufacturing (MAM), particularly Powder Bed Fusion (LPBF), offers significant opportu- nities for improving material efficiency but suffers from slow build rates and low energy effi- ciency, limiting its environmental benefits and widespread adoption due to high costs and re- quired post-processing. Conversely, Wire Arc Additive Manufacturing (WAAM), an emerging Di- rected Energy Deposition (DED) technology, offers higher build rates suitable for large parts with more affordable machine tools. However, WAAM parts often require additional machining and heat treatments due to issues like high residual stresses and poor surface finish, impacting its sustainability. Considering these opportunities and challenges, it is essential to ensure WAAM's sustainable development through Life Cycle Sustainability Assessment (LCSA) that encompasses its environmental, economic, and social dimensions. This PhD work aims to comprehensively as- sess WAAM's performance in terms of environmental impact, manufacturing costs, and social impacts, focusing on industrial applications. Using Life Cycle Assessment (LCA), Life Cycle Costing (LCC), and Social Life Cycle Assessment (S-LCA) methodologies, environmental impacts, costs and social impacts of WAAM are evaluated. Additionally, the mechanical properties imparted by WAAM parts are characterized and compared with LPBF and CNC machining. Furthermore, an online LCSA tool enabling designers and engineers to compare the sustainability of WAAM, and traditional CNC machining approaches is developed, facilitating the selection of the most sus- tainable manufacturing processes. The insights gained will be helpful for decision-makers in re- ducing the environmental footprint, optimizing costs, mitigating adverse social impacts, thereby promoting sustainability from the eary stages of product 's life cycle. |
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