Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components

Huang, Runze; Riddle, Matthew; Graziano, Diane; Warren, Joshua; Das, Sujit; Nimbalkar, Sachin; Cresko, Joe; Masanet, Eric

doi:10.1016/j.jclepro.2015.04.109

Title: Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components

Journal Article · Tue Nov 01 00:00:00 EDT 2016 · Journal of Cleaner Production

DOI:https://doi.org/10.1016/j.jclepro.2015.04.109· OSTI ID:1404714

; Riddle, Matthew; Graziano, Diane; Warren, Joshua; Das, Sujit;

; Cresko, Joe; Masanet, Eric

Additive manufacturing (AM) holds great potential for improving materials efficiency, reducing life-cycle impacts, and enabling greater engineering functionality compared to conventional manufacturing (CM), and AM has been increasingly adopted by aircraft component manufacturers for lightweight, cost-effective designs. This study estimates the net changes in life-cycle primary energy and greenhouse gas emissions associated with AM technologies for lightweight metallic aircraft components through the year 2050, to shed light on the environmental benefits of a shift from CM to AM processes in the U.S. aircraft industry. A systems modeling framework is presented, with integrates engineering criteria, life-cycle environmental data, aircraft fleet stock and fuel use models under different AM adoption scenarios. Estimated fleet-wide life-cycle primary energy savings at most reach 70-173 million GJ/year in 2050, with cumulative savings of 1.2–2.8 billion GJ. Associated cumulative GHG emission reductions were estimated at 92.1–215.0 million metric tons. In addition, thousands of tons of aluminum, titanium and nickel alloys could be potentially saved per year in 2050. The results indicate a significant role of AM technologies in helping society meet its long-term energy use and GHG emissions reduction goals, and highlight barriers and opportunities for AM adoption for the aircraft industry.

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Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE) - Advanced Manufacturing Office

DOE Contract Number:: AC02-06CH11357

OSTI ID:: 1404714

Journal Information:: Journal of Cleaner Production, Vol. 135, Issue C; ISSN 0959-6526

Publisher:: Elsevier

Country of Publication:: United States

Language:: English

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32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
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