Critical life cycle inventory for aluminum die casting: A lightweight-vehicle manufacturing enabling technology

One of the major challenges for manufacturing companies is finding opportunities to implement green and transparent operational processes to meet a set of macro-economic targets which are defined in strategic initiatives such as the 2030 Agenda for Sustainable Development, the European Green Deal, and the Paris Agreement. Although, in this context, Life Cycle Assessment (LCA) has become established as a common method for assessing the environmental impact of products or processes, in practice problems often arise due to a large amount of data and information to be processed and the resources required. In this regard, recent Industry 4.0 technologies can be seen as a potential enabler of an automated “smart” life cycle assessment in manufacturing companies. Therefore, this paper systematically reviews the current literature on “smart” LCA implementations and presents a comprised overview of the generic properties of “smart” LCA implementations using a general morphological analysis. The research results of this paper can be used for the further development of a “smart” LCA for science and practical applications, as well. 

Harmonizing “Smart” Life Cycle Assessment in Manufacturing Companies: Literature Review and Preliminary Morphological Analysis

Conventional manufacturing techniques have not been subject to much scrutiny by industrial ecologists to date. Many newer techniques and products draw more attention as they rise quickly from research to global scales, amplifying their environmental consequences. Despite the presence of new technologies and increased overseas production, casting activity continues to have a strong presence in the US, and represents a stable component in the national economy. Data from the US government, US industry groups, and UK mass balance profiles facilitate an understanding of sand casting and comparison across manufacturing processes. The figures in the US and UK are similar in terms of diversity of metals (where the US is 72%, 13%, 10% and the UK 76%, 13%, 8% for iron, aluminum, and steel, respectively), energy per ton of saleable cast metal (10.1 and 9.3 million Btu/ton in the US and UK), and overall emissions, with notable similarities in benzene and particulate emissions. One notable discrepancy is in sand use, where the US sends to waste 0.5 tons of sand per ton of cast metal, whereas the UK sends 0.25 tons to landfill.Copyright © 2004 by ASME

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Life Cycle Analysis of Conventional Manufacturing Techniques: Sand Casting

As part of an ongoing project, a life cycle inventory (LCI) of aluminium high pressure die casting (HPDC) has been collected. This has been conducted from the view of an individual product and also the entire process. The objective of the study was to analyse the process and suggest changes to reduce environmental impacts. One modem aluminium high pressure die casting plant located in Victoria, Australia was evaluated and modelled. Site specific data on energy and materials was gathered and the process was modelled using a typical automotive component. The paper also presents our experience and methodology used in this inventory data collection process from the real industry for LCA purposes. The inventory data collected itself reveals that the HPDC process is energy intensive and as such the major emissions were from the use of natural gas fired furnaces and from the brown coal derived electricity. It is also found the large environmental benefits of using secondary aluminium over primary aluminium in the HPDC process. A detailed LCA is being cal1ied out based on the inventory obtained.

/pdf/a-life-cycle-inventory-of-aluminium-die-casting-peyvn5urme.pdf

A life cycle inventory of aluminium die casting

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A life cycle inventory of aluminium die casting