scholarly journals Integration of Simulation Driven DfAM and LCC Analysis for Decision Making in L-PBF

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1179
Author(s):  
Patricia Nyamekye ◽  
Anna Unt ◽  
Antti Salminen ◽  
Heidi Piili
Keyword(s):  
Decision Making ◽  
Life Cycle ◽  
Additive Manufacturing ◽  
Life Cycle Cost ◽  
Practical Case ◽  
Layer By Layer ◽  
Powder Bed ◽  
Traditional Manufacturing ◽  
Application Fields ◽  
The Impact

Laser based powder bed fusion (L-PBF) is used to manufacture parts layer by layer with the energy of laser beam. The use of L-PBF for building functional parts originates from the design freedom, flexibility, customizability, and energy efficiency of products applied in dynamic application fields such as aerospace and automotive. There are challenges and drawbacks that need to be defined and overcome before its adaptation next to rivaling traditional manufacturing methods. Factors such as high cost of L-PBF machines, metal powder, post-preprocessing, and low productivity may deter its acceptance as a mainstream manufacturing technique. Understanding the key cost drivers of L-PBF that influence productivity throughout the whole lifespan of products will facilitate the decision-making process. Functional and operational decisions can yield profitability and increase competitiveness among advanced manufacturing sectors. Identifying the relationships between the phases of the life cycle of products influences cost-effectiveness. The aim of the study is to investigate the life cycle cost (LCC) and the impact of design to it in additive manufacturing (AM) with L-PBF. The article provides a review of simulation driven design for additive manufacturing (simulation driven DfAM) and LCC for metallic L-PBF processes and examines the state of the art to outline the merits, demerits, design rules, and life cycle models of L-PBF. Practical case studies of L-PBF are discussed and analysis of the interrelating factors of the different life phases are presented. This study shows that simulation driven DfAM in the design phase increases the productivity throughout the whole production and life span of L-PBF parts. The LCC model covers the whole holistic lifecycle engineering of products and offers guidelines for decision making.

scholarly journals A STRUCTURED APPROACH TO REDUCE DESIGN ITERATIONS IN ADDITIVE MANUFACTURING

2021 ◽  
Vol 1 ◽  
pp. 231-240
Author(s):  
Laura Wirths ◽  
Matthias Bleckmann ◽  
Kristin Paetzold
Keyword(s):  
Additive Manufacturing ◽  
Spare Parts ◽  
Design Guidelines ◽  
Final Part ◽  
Layer By Layer ◽  
Powder Bed ◽  
Batch Sizes ◽  
Manufacturing Technologies ◽  
Structured Approach ◽  
Design Freedom

AbstractAdditive Manufacturing technologies are based on a layer-by-layer build-up. This offers the possibility to design complex geometries or to integrate functionalities in the part. Nevertheless, limitations given by the manufacturing process apply to the geometric design freedom. These limitations are often unknown due to a lack of knowledge of the cause-effect relationships of the process. Currently, this leads to many iterations until the final part fulfils its functionality. Particularly for small batch sizes, producing the part at the first attempt is very important. In this study, a structured approach to reduce the design iterations is presented. Therefore, the cause-effect relationships are systematically established and analysed in detail. Based on this knowledge, design guidelines can be derived. These guidelines consider process limitations and help to reduce the iterations for the final part production. In order to illustrate the approach, the spare parts production via laser powder bed fusion is used as an example.

scholarly journals Life Cycle Assessment of Railway Ground-Borne Noise and Vibration Mitigation Methods Using Geosynthetics, Metamaterials and Ground Improvement

2018 ◽  
Vol 10 (10) ◽  
pp. 3753 ◽  
Author(s):  
Sakdirat Kaewunruen ◽  
Victor Martin
Keyword(s):  
Life Cycle ◽  
Life Cycle Cost ◽  
Ground Improvement ◽  
Cycle Performance ◽  
Vibration Mitigation ◽  
Noise And Vibration ◽  
Climate Conditions ◽  
Extreme Climate ◽  
Mitigation Methods ◽  
The Impact

Significant increase in the demand for freight and passenger transports by trains pushes the railway authorities and train companies to increase the speed, the axle load and the number of train carriages/wagons. All of these actions increase ground-borne noise and vibrations that negatively affect people who work, stay, or reside nearby the railway lines. In order to mitigate these phenomena, many techniques have been developed and studied but there is a serious lack of life-cycle information regarding such the methods in order to make a well-informed and sustainable decision. The aim of this study is to evaluate the life-cycle performance of mitigation methods that can enhance sustainability and efficacy in the railway industry. The emphasis of this study is placed on new methods for ground-borne noise and vibration mitigation including metamaterials, geosynthetics, and ground improvement. To benchmark all of these methods, identical baseline assumptions and the life-cycle analysis over 50 years have been adopted where relevant. This study also evaluates and highlights the impact of extreme climate conditions on the life-cycle cost of each method. It is found that the anti-resonator method is the most expensive methods compared with the others whilst the use of geogrids (for subgrade stiffening) is relatively reliable when used in combination with ground improvements. The adverse climate has also played a significant role in all of the methods. However, it was found that sustainable methods, which are less sensitive to extreme climate, are associated with the applications of geosynthetic materials such as geogrids, composites, etc.

scholarly journals Effects of Positioning Conditions on Material Properties In Powder bed Fusion Additive Manufacturing

2021 ◽  
Author(s):  
Mevlüt Yunus Kayacan ◽  
Nihat Yılmaz
Keyword(s):  
Additive Manufacturing ◽  
Material Properties ◽  
Layer By Layer ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Cooling Rates ◽  
Powder Bed ◽  
Manufacturing Technologies ◽  
Average Size ◽  
Hardness Values

Abstract Among additive manufacturing technologies, Laser Powder Bed Fusion (L-PBF) is considered the most widespread layer-by-layer process. Although the L-PBF, which is also called as SLM method, has many advantages, several challenging problems must be overcome, including part positioning issues. In this study, the effect of part positioning on the microstructure of the part in the L-PBF method was investigated. Five Ti6Al4V samples were printed in different positions on the building platform and investigated with the aid of temperature, porosity, microstructure and hardness evaluations. In this study, martensitic needles were detected within the microstructure of Ti6Al4V samples. Furthermore, some twins were noticed on primary martensitic lines and the agglomeration of β precipitates was observed in vanadium rich areas. The positioning conditions of samples were revealed to have a strong effect on temperature gradients and on the average size of martensitic lines. Besides, different hardness values were attained depending on sample positioning conditions. As a major result, cooling rates were found related to positions of samples and the location of point on the samples. Higher cooling rates and repetitive cooling cycles resulted in microstructures becoming finer and harder.

Comparing Environmental Impacts of Additive Manufacturing vs. Investment Casting for the Production of a Shroud for Gas Turbine

2021 ◽  
Author(s):  
Angela Serra ◽  
Martina Malarco ◽  
Alessandro Musacchio ◽  
Giulio Buia ◽  
Pietro Bartocci ◽  
...  
Keyword(s):  
Life Cycle ◽  
Additive Manufacturing ◽  
Environmental Impact ◽  
Investment Casting ◽  
Gas Turbines ◽  
Raw Materials ◽  
Base Material ◽  
Small Scale ◽  
Atomization Process ◽  
Traditional Manufacturing

Abstract Additive manufacturing (AM hereinafter) is revolutionizing prototyping production and even small-scale manufacturing. Usually it is assumed that AM has lower environmental impact, compared to traditional manufacturing processes, but there have been no comprehensive environmental life-cycle assessment studies confirming this, especially for the gas turbines (GT hereinafter) and turbomachinery sector. In this study the core processes performed at Baker Hughes site in Florence are considered, together with the powder production via atomization process to describe the overall environmental impact of a GT shroud produced through additive manufacturing and comparing it with traditional investment casting production process. Particular attention is given to materials production and logistics. The full component life cycle starts from the extraction of raw materials during mining, their fusion and, as said, the atomization process, the powders are transported to the gas turbines production site where they are used as base material in additive manufacturing, also machining and finishing processes are analyzed as they differ for a component produced by AM respect to one produced by traditional investment casting. From the analysis of the data obtained, it emerges that the AM process has better performances in terms of sustainability than the Investment casting (IC hereinafter), highlighted above all by a decrease in greenhouse gas emissions (GHG hereinafter) of over 40%.

Additive Manufacturing of Nickel-Based Super Alloys for Aero Engine Applications

2020 ◽  
pp. 48-70
Author(s):  
Raja A. ◽  
Mythreyi O. V. ◽  
Jayaganthan R.
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Source Parameters ◽  
Raw Material ◽  
Layer By Layer ◽  
Powder Bed ◽  
Complex Design ◽  
Direct Energy ◽  
Second Phases ◽  
Metal Addition

Ni based super alloys are widely used in engine turbines because of their proven performance at high temperatures. Manufacturing these parts by additive manufacturing (AM) methods provides researchers a lot of creative space for complex design to improve efficiency. Powder bed fusion (PBF) and direct energy deposition (DED) are the two most widely-used metal AM methods. Both methods are influenced by the source, parameters, design, and raw material. Selective laser melting is one of the laser-based PBF techniques to create small layer thickness and complex geometry with greater accuracy and properties. The layer-by-layer metal addition generates epitaxial growth and solidification in the built direction. There are different second phases in the Ni-based superalloys. This chapter details the micro-segregation of these particles and its influence on the microstructure, and mechanical properties are dependent on the process influencing parameters, the thermal kinetics during the process, and the post-processing treatments.

From Sketches and Installations to Bioinspired 5D Printing Models

2021 ◽  
pp. 365-387
Author(s):  
Silvia Titotto
Keyword(s):  
Decision Making ◽  
Additive Manufacturing ◽  
Future Development ◽  
Smart Cities ◽  
Virtual Prototyping ◽  
Interdisciplinary Approach ◽  
Biologically Inspired ◽  
Digital Twins ◽  
Cad Cam ◽  
The Impact

This chapter opens up discussions upon the relevance of interaction of representations and data visualization modes for smart cities design, planning, and development that occur beyond paper and computer drawing. Although many practitioners usually relate smart cities and digital twins design exclusively to CAD/CAM/CAE and BIM methods, processes, and tools, a wider pool of techniques and forms of expression might be the key to a more accurate and comprehensive way of simulating the several kinds of alterations that happen in the planned built environment. The chapter deals with the study of concepts that relate to both physical and virtual prototyping, which underlines an interdisciplinary approach to design and the impact of integrating biologically inspired principles from different backgrounds to the field of smart cities design. In this regard, biomimetics and additive manufacturing may play key roles in smart city's modeling design and the frontier technology of 5D printing reveals real-time decision-making programmable 4D printing process as a potential future development.

scholarly journals The Impact Assessment of Campus Buildings Based on a Life Cycle Assessment–Life Cycle Cost Integrated Model

2019 ◽  
Vol 12 (1) ◽  
pp. 294 ◽  
Author(s):  
Zhuyuan Xue ◽  
Hongbo Liu ◽  
Qinxiao Zhang ◽  
Jingxin Wang ◽  
Jilin Fan ◽  
...  
Keyword(s):  
Life Cycle Assessment ◽  
Life Cycle ◽  
Environmental Impacts ◽  
Life Cycle Cost ◽  
Electric Energy ◽  
Integrated Model ◽  
Economic Costs ◽  
Analytic Hierarchy ◽  
The Sustainable Development ◽  
The Impact

The development of higher education has led to an increasing demand for campus buildings. To promote the sustainable development of campus buildings, this paper combines social willingness-to-pay (WTP) with the analytic hierarchy process (AHP) based on the characteristics of Chinese campus buildings to establish a life cycle assessment–life cycle cost (LCA–LCC) integrated model. Based on this model, this paper analyses the teaching building at a university in North China. The results show that the environmental impacts and economic costs are largest in the operation phase of the life cycle, mainly because of the use of electric energy. The environmental impacts and economic costs during the construction phase mainly come from the building material production process (BMPP); in this process, steel is the main source. Throughout the life cycle, abiotic depletion-fossil fuel potential (ADP fossil) and global warming potential (GWP) are the most prominent indexes. Further analysis shows that these two indexes should be the emphases of similar building assessments in the near future. Finally, this study offers suggestions for the proposed buildings and existing buildings based on the prominent problems found in the case study, with the aim to provide reference for the design, construction, and operation management of similar buildings.

scholarly journals Framework for Life Cycle Sustainability Assessment of Additive Manufacturing

2020 ◽  
Vol 12 (3) ◽  
pp. 929 ◽  
Author(s):  
Ribeiro ◽  
Matos ◽  
Jacinto ◽  
Salman ◽  
Cardeal ◽  
...  
Keyword(s):  
Life Cycle ◽  
Additive Manufacturing ◽  
Sustainability Assessment ◽  
Value Chains ◽  
Illustrative Case ◽  
Bottom Line ◽  
Disruptive Technologies ◽  
The People ◽  
Specific Dimension ◽  
Traditional Manufacturing

Additive manufacturing (AM) is a group of technologies that create objects by adding material layer upon layer, in precise geometric shapes. They are amongst the most disruptive technologies nowadays, potentially changing value chains from the design process to the end-of-life, providing significant advantages over traditional manufacturing processes in terms of flexibility in design and production and waste minimization. Nevertheless, sustainability assessment should also be included in the research agenda as these technologies affect the People, the Planet and the Profit: the three-bottom line (3BL) assessment framework. Moreover, AM sustainability depends on each product and context that strengthens the need for its assessment through the 3BL framework. This paper explores the literature on AM sustainability, and the results are mapped in a framework aiming to support comprehensive assessments of the AM impacts in the 3BL dimensions by companies and researchers. To sustain the coherence of boundaries, three life cycle methods are proposed, each one for a specific dimension of the 3BL analysis, and two illustrative case studies are shown to exemplify the model.

Sustainable construction

2020 ◽  
Vol 20 (2) ◽  
pp. 191-207 ◽  
Author(s):  
Muhammad Waseem Khan ◽  
Yousaf Ali
Keyword(s):  
Life Cycle ◽  
Rice Husk ◽  
Life Cycle Cost ◽  
Sustainable Construction ◽  
Partial Replacement ◽  
Content Type ◽  
Government Organizations ◽  
Construction Companies ◽  
Concrete Type ◽  
The Impact

Purpose The change in climate and depletion of natural resources because of the harmful emissions from different materials becomes a main issue for the globe. Some of the developed and developing countries have focused on this issue and performed research to provide a solution. The purpose of this study is to identify the best types of concrete based on its impact on the environment and economy. Design/methodology/approach The life cycle assessment and life cycle cost analysis of six concrete mixtures that include construction and demolition wastes (CDW), marble sludge, rice husk and bagasse ash as a partial replacement of cement, are performed. These types of concrete are compared with each other and with ordinary concrete to select the best possible concrete type for a developing country, like Pakistan. Findings The results show that, although for an agricultural country like Pakistan, the agriculture wastes such as rice husk and bagasse ash are preferable to be used, if the emissions of CO2 and CO from rice husk and NOx and SO2 from bagasse ash are properly controlled. However, based on the results, it is recommended to use the CDW in concrete because of the small amount of air emissions and affordable prices. Originality/value Through this study, a path has been provided to construction companies and relative government organizations of Pakistan, which leads to sustainable practices in the construction industry. Moreover, the base is provided for future researchers who want to work in this area, as for Pakistan, there is no database available that helps to identify the impact of different concrete on the environment.

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