Assessment of the carbon reduction potential of the hybrid deposition and micro-rolling (HDMR) for aviation forgings based on industrial metabolism

Purpose Conventional manufacturing (CM) methods for complex forgings involve high energy consumption and substantial carbon emissions, posing significant environmental challenges. This study aims to evaluate the emissions of hybrid deposition and micro-rolling (HDMR) technology compared with CM in producing aviation forgings, assessing its feasibility as a sustainable alternative. Design/methodology/approach Using an industrial metabolism model based on carbon sources, this study conducts a carbon accounting analysis of the manufacturing process for an aircraft landing gear external cylinder. The carbon emission performance of HDMR and CM methods is evaluated and compared along two key dimensions: raw material consumption and energy usage. Findings The results show that the total CO2 output of the HDMR method for manufacturing the external cylinder are reduced by a coefficient of 32 compared to the CM method, and the metal raw material consumption is reduced by 85.40%. Originality/value This study proposes a novel industrial metabolism model to assess carbon emissions in HDMR processes. The results confirm the potential of HDMR to significantly reduce carbon footprint and material consumption in forging manufacturing, thereby supporting the transition of industry to low-carbon production.