Details
| Original language | English |
|---|---|
| Article number | 117355 |
| Number of pages | 12 |
| Journal | Engineering structures |
| Volume | 301 |
| Early online date | 21 Dec 2023 |
| Publication status | Published - 15 Feb 2024 |
Abstract
Wire arc additive manufacturing (WAAM) enables the manufacturing of efficient and lightweight structural elements in which material can be utilised wherever needed in an optimised shape, in contrast to standard prismatic profiles used in construction. However, the specific energy consumption (SEC) of WAAM is higher than that of conventional manufacturing (CM) techniques (i.e., hot-rolling) for standard profiles. Therefore, it is an open question whether the material savings through computational design realised via WAAM is environmentally beneficial or not. This systematic study aims to provide a better understanding of the environmental impact of hybrid manufacturing, which is defined as the combination of WAAM and CM rather than using any of them alone. Topology optimisation (TO) is used to design a series of beams with an identical performance (i.e., stiffness) but with a reduced material consumption depending on the hybrid ratio. The environmental impact of the designs has been used to determine when and how hybridisation can become advantageous. The results show that although the optimal proportions of WAAM and CM are dependent on their relative SEC, the hybrid solutions have always been environmentally superior compared to that of WAAM or CM alone for the realistic SEC values, exhibiting up to a 60% reduction in environmental impact compared to that of CM.
Keywords
- Design for sustainability, Environmental assessment, Hybrid manufacturing, Metal additive manufacturing, Topology optimisation
ASJC Scopus subject areas
- Engineering(all)
- Civil and Structural Engineering
Sustainable Development Goals
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In: Engineering structures, Vol. 301, 117355, 15.02.2024.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Design optimisation for hybrid metal additive manufacturing for sustainable construction
AU - Baqershahi, Mohammad Hassan
AU - Ayas, Can
AU - Ghafoori, Elyas
N1 - Funding information: We gratefully thank Prof. van Keulen (Delft University of Technology) for providing invaluable guidance and insights that were critical in shaping this work.
PY - 2024/2/15
Y1 - 2024/2/15
N2 - Wire arc additive manufacturing (WAAM) enables the manufacturing of efficient and lightweight structural elements in which material can be utilised wherever needed in an optimised shape, in contrast to standard prismatic profiles used in construction. However, the specific energy consumption (SEC) of WAAM is higher than that of conventional manufacturing (CM) techniques (i.e., hot-rolling) for standard profiles. Therefore, it is an open question whether the material savings through computational design realised via WAAM is environmentally beneficial or not. This systematic study aims to provide a better understanding of the environmental impact of hybrid manufacturing, which is defined as the combination of WAAM and CM rather than using any of them alone. Topology optimisation (TO) is used to design a series of beams with an identical performance (i.e., stiffness) but with a reduced material consumption depending on the hybrid ratio. The environmental impact of the designs has been used to determine when and how hybridisation can become advantageous. The results show that although the optimal proportions of WAAM and CM are dependent on their relative SEC, the hybrid solutions have always been environmentally superior compared to that of WAAM or CM alone for the realistic SEC values, exhibiting up to a 60% reduction in environmental impact compared to that of CM.
AB - Wire arc additive manufacturing (WAAM) enables the manufacturing of efficient and lightweight structural elements in which material can be utilised wherever needed in an optimised shape, in contrast to standard prismatic profiles used in construction. However, the specific energy consumption (SEC) of WAAM is higher than that of conventional manufacturing (CM) techniques (i.e., hot-rolling) for standard profiles. Therefore, it is an open question whether the material savings through computational design realised via WAAM is environmentally beneficial or not. This systematic study aims to provide a better understanding of the environmental impact of hybrid manufacturing, which is defined as the combination of WAAM and CM rather than using any of them alone. Topology optimisation (TO) is used to design a series of beams with an identical performance (i.e., stiffness) but with a reduced material consumption depending on the hybrid ratio. The environmental impact of the designs has been used to determine when and how hybridisation can become advantageous. The results show that although the optimal proportions of WAAM and CM are dependent on their relative SEC, the hybrid solutions have always been environmentally superior compared to that of WAAM or CM alone for the realistic SEC values, exhibiting up to a 60% reduction in environmental impact compared to that of CM.
KW - Design for sustainability
KW - Environmental assessment
KW - Hybrid manufacturing
KW - Metal additive manufacturing
KW - Topology optimisation
UR - http://www.scopus.com/inward/record.url?scp=85180771800&partnerID=8YFLogxK
U2 - 10.1016/j.engstruct.2023.117355
DO - 10.1016/j.engstruct.2023.117355
M3 - Article
AN - SCOPUS:85180771800
VL - 301
JO - Engineering structures
JF - Engineering structures
SN - 0141-0296
M1 - 117355
ER -