Life Cycle Assessment of Cold Spray Additive Manufacturing and Conventional Machining of Aluminum Alloy Flange

Dileep  Kumar; Suresh Palanisamy; Kannoorpatti Krishnan; Md Morshed Alam

doi:10.3390/met13101684

Life Cycle Assessment of Cold Spray Additive Manufacturing and Conventional Machining of Aluminum Alloy Flange

Dileep Kumar, Suresh Palanisamy, Kannoorpatti Krishnan, Md Morshed Alam

Energy and Resources Institute

Research output: Contribution to journal › Article › peer-review

5 Citations (Scopus)

122 Downloads (Pure)

Abstract

Cold spray additive manufacturing (CSAM) is generally used to repair worn components and build complex on-demand parts by depositing metal powder layer-wise using compressed air. Previous studies on CSAM were focused on printing parameters, materials properties, and printed part mechanical performance. However, the energy consumption and environmental impacts of CSAM processes have not yet been investigated, which are essential factors for sustainable manufacturing. This study aims to investigate the carbon footprint of the CSAM process and compare it with conventional machining processes and other additive manufacturing. The life cycle assessment methodology was followed to calculate the carbon footprint of a pipe flange, considering rod or tube as a feedstock. Results revealed that the machined flange from the tube had the lowest CO_2-eq emissions of 31 kg CO_2-eq due to low rough machining energy consumption and scrap production, compared to the machined flange from a rod and a printed flange from powder. Moreover, the life cycle carbon emissions increased by 8% and 19% in case of the printed and machined flanges, with uncertainties of 4% and 9%, respectively, when changing feedstock CO₂ emissions. From a regional perspective, the CSAM process was responsible for the lowest CO_2-eq emissions in Tasmania and South Australia.

Original language	English
Article number	1684
Pages (from-to)	1-21
Number of pages	21
Journal	Metals
Volume	13
Issue number	10
DOIs	https://doi.org/10.3390/met13101684
Publication status	Published - Oct 2023

Bibliographical note

Funding Information:
This research was funded by AUSTRALIAN POSTGRADUATE RESEARCH, grant number int-1114″. APR.Intern (aprintern.org.au).

Funding Information:
This research was supported by the Australian Postgraduate Research Internship program and SPEE3D. The authors would like to acknowledge the support of Novana Hutosait and Mohammed Abdul Khaliq from Swinburne University of Technology, and Byron Kennedy and Steve Camilleri from SPEE3D, Australia, for their in-kind support.

Publisher Copyright:
© 2023 by the authors.

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.3390/met13101684

88446354-oaFinal published version, 3.61 MBLicence: CC BY

http://www.mdpi.com/2075-4701/13/10/1684Licence: CC BY

Cite this

@article{e13975c08bbd41469030a0a52ff37685,

title = "Life Cycle Assessment of Cold Spray Additive Manufacturing and Conventional Machining of Aluminum Alloy Flange",

abstract = "Cold spray additive manufacturing (CSAM) is generally used to repair worn components and build complex on-demand parts by depositing metal powder layer-wise using compressed air. Previous studies on CSAM were focused on printing parameters, materials properties, and printed part mechanical performance. However, the energy consumption and environmental impacts of CSAM processes have not yet been investigated, which are essential factors for sustainable manufacturing. This study aims to investigate the carbon footprint of the CSAM process and compare it with conventional machining processes and other additive manufacturing. The life cycle assessment methodology was followed to calculate the carbon footprint of a pipe flange, considering rod or tube as a feedstock. Results revealed that the machined flange from the tube had the lowest CO2-eq emissions of 31 kg CO2-eq due to low rough machining energy consumption and scrap production, compared to the machined flange from a rod and a printed flange from powder. Moreover, the life cycle carbon emissions increased by 8% and 19% in case of the printed and machined flanges, with uncertainties of 4% and 9%, respectively, when changing feedstock CO2 emissions. From a regional perspective, the CSAM process was responsible for the lowest CO2-eq emissions in Tasmania and South Australia.",

keywords = "cold spray additive manufacturing, conventional machining, energy consumption, life cycle assessment, SPEE3D printer",

author = "Dileep Kumar and Suresh Palanisamy and Kannoorpatti Krishnan and Alam, {Md Morshed}",

note = "Funding Information: This research was funded by AUSTRALIAN POSTGRADUATE RESEARCH, grant number int-1114″. APR.Intern (aprintern.org.au). Funding Information: This research was supported by the Australian Postgraduate Research Internship program and SPEE3D. The authors would like to acknowledge the support of Novana Hutosait and Mohammed Abdul Khaliq from Swinburne University of Technology, and Byron Kennedy and Steve Camilleri from SPEE3D, Australia, for their in-kind support. Publisher Copyright: {\textcopyright} 2023 by the authors.",

year = "2023",

month = oct,

doi = "10.3390/met13101684",

language = "English",

volume = "13",

pages = "1--21",

journal = "Metals",

issn = "2075-4701",

publisher = "Multidisciplinary Digital Publishing Institute (MDPI)",

number = "10",

}

TY - JOUR

T1 - Life Cycle Assessment of Cold Spray Additive Manufacturing and Conventional Machining of Aluminum Alloy Flange

AU - Kumar, Dileep

AU - Palanisamy, Suresh

AU - Krishnan, Kannoorpatti

AU - Alam, Md Morshed

N1 - Funding Information: This research was funded by AUSTRALIAN POSTGRADUATE RESEARCH, grant number int-1114″. APR.Intern (aprintern.org.au). Funding Information: This research was supported by the Australian Postgraduate Research Internship program and SPEE3D. The authors would like to acknowledge the support of Novana Hutosait and Mohammed Abdul Khaliq from Swinburne University of Technology, and Byron Kennedy and Steve Camilleri from SPEE3D, Australia, for their in-kind support. Publisher Copyright: © 2023 by the authors.

PY - 2023/10

Y1 - 2023/10

N2 - Cold spray additive manufacturing (CSAM) is generally used to repair worn components and build complex on-demand parts by depositing metal powder layer-wise using compressed air. Previous studies on CSAM were focused on printing parameters, materials properties, and printed part mechanical performance. However, the energy consumption and environmental impacts of CSAM processes have not yet been investigated, which are essential factors for sustainable manufacturing. This study aims to investigate the carbon footprint of the CSAM process and compare it with conventional machining processes and other additive manufacturing. The life cycle assessment methodology was followed to calculate the carbon footprint of a pipe flange, considering rod or tube as a feedstock. Results revealed that the machined flange from the tube had the lowest CO2-eq emissions of 31 kg CO2-eq due to low rough machining energy consumption and scrap production, compared to the machined flange from a rod and a printed flange from powder. Moreover, the life cycle carbon emissions increased by 8% and 19% in case of the printed and machined flanges, with uncertainties of 4% and 9%, respectively, when changing feedstock CO2 emissions. From a regional perspective, the CSAM process was responsible for the lowest CO2-eq emissions in Tasmania and South Australia.

AB - Cold spray additive manufacturing (CSAM) is generally used to repair worn components and build complex on-demand parts by depositing metal powder layer-wise using compressed air. Previous studies on CSAM were focused on printing parameters, materials properties, and printed part mechanical performance. However, the energy consumption and environmental impacts of CSAM processes have not yet been investigated, which are essential factors for sustainable manufacturing. This study aims to investigate the carbon footprint of the CSAM process and compare it with conventional machining processes and other additive manufacturing. The life cycle assessment methodology was followed to calculate the carbon footprint of a pipe flange, considering rod or tube as a feedstock. Results revealed that the machined flange from the tube had the lowest CO2-eq emissions of 31 kg CO2-eq due to low rough machining energy consumption and scrap production, compared to the machined flange from a rod and a printed flange from powder. Moreover, the life cycle carbon emissions increased by 8% and 19% in case of the printed and machined flanges, with uncertainties of 4% and 9%, respectively, when changing feedstock CO2 emissions. From a regional perspective, the CSAM process was responsible for the lowest CO2-eq emissions in Tasmania and South Australia.

KW - cold spray additive manufacturing

KW - conventional machining

KW - energy consumption

KW - life cycle assessment

KW - SPEE3D printer

UR - http://www.scopus.com/inward/record.url?scp=85175035081&partnerID=8YFLogxK

U2 - 10.3390/met13101684

DO - 10.3390/met13101684

M3 - Article

AN - SCOPUS:85175035081

SN - 2075-4701

VL - 13

SP - 1

EP - 21

JO - Metals

JF - Metals

IS - 10

M1 - 1684

ER -

Life Cycle Assessment of Cold Spray Additive Manufacturing and Conventional Machining of Aluminum Alloy Flange

Abstract

Bibliographical note

UN SDGs

Access to Document

Other files and links

Fingerprint

Cite this