Comparison of energy consumption between hybrid deposition & micro-rolling and conventional approach for wrought parts. (10th January 2021)

• Record Type: Journal Article
• Authors: Zhang, Haiou; Huang, Cheng; Wang, Guilan; Li, Runsheng; Zhao, Gang
• Is Part Of: Journal of cleaner production. Volume 279(2021)
• Publication Date: 2021-01-10
• Subjects: Additive manufacturing -- Hybrid deposition and micro rolling -- Energy consumption -- Energy efficiency -- Conventional forging; Factory and trade waste -- Management -- Periodicals; Manufactures -- Environmental aspects -- Periodicals; Déchets industriels -- Gestion -- Périodiques; Usines -- Aspect de l'environnement -- Périodiques; 628.5
• DOI: 10.1016/j.jclepro.2020.123307
• Languages: English
• ISSNs: 0959-6526

Abstract

Abstract: The conventional approaches for wrought parts involve excessive energy consumption and severe pollution due to enormous equipment, the repeated heating and forging processes, and low material utilization. The hybrid deposition and micro rolling (HDMR), which combines in-situ rolling with additive manufacturing by applying synchronous pressure on the deposited layer with a micro-roller, is introduced to addresses the above challenges. To investigate the environmental performance of the HDMR process, this research develops an energy model based on active energy consumption and energy efficiency, which is verified with a deviation of 11.3% by power monitoring. A comprehensively comparative assessment is carried out between the conventional methods and HDMR for the fabrication of a wrought Ti-6Al-4V component. It is demonstrated that HDMR consumes only 35% energy of conventional approaches and shows superior performance in mechanical properties and production procedures. The energy efficiency of the deforming process in HDMR is estimated to be ∼150-fold higher than that of conventional forging processes. Thus, HDMR is expected to be a promising substitute for conventional approaches to fabricate wrought components and facilitates the green transformation of traditional forging approaches. Highlights: Wrought parts fabrication by additive manufacturing. The micro roller achieves the same effect as the forging press of thousands of tons. Set up an energy model based on active work and energy efficiency. Approximately ∼150-fold improvement of energy efficiency in the deforming process. A promising and clean substitute for conventional forging approach.