Comparative Life Cycle and Machinability Assessment of Milling WAAM and Wrought Inconel 925
Source abstract
Abstract
One of the significant challenges the manufacturing industry faces is creating sustainable machining processes that strike a balance between economic productivity and energy consumption. To address this challenge, this work is focused on a comprehensive life cycle assessment (LCA) analysis and machinability analysis during the milling of wrought and wire arc additively manufactured (WAAMed) Inconel 925 (IN925). In addition, the work offers an in-depth description of the steps essential to conduct LCA. Four conditions are used for machining experiments: dry, flood cooling, minimum quantity lubrication (MQL), and hybrid nanofluid MQL (HNMQL). LCA is performed for 18 environmental impact categories using the ReCiPe 2016 Midpoint (H) impact assessment method. The comparison study demonstrated the potential benefits of additive manufacturing, especially in terms of lower material waste and energy efficiency. Using HNMQL reduced surface roughness by approximately 19-46% for wrought and 25-51% for WAAMed IN925. Further, the tool wear under HNMQL is reduced by 11% and 32% than MQL and flood cooling. Applying hybrid nanofluid MQL revealed a good balance between machinability and environmental effects for machining WAAMed IN925. However, the interpretation also underscored the critical role of the machining phase, urging industries to prioritize optimization strategies and innovative cooling techniques to minimize environmental impacts further.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Advanced machining processes and optimization · Manufacturing Process and Optimization · Advanced Machining and Optimization Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (62)
Show source-provided references
1. G.S. Goindi and P. Sarkar, Dry Machining: A Step Towards Sustainable Machining – Challenges and Future Directions, J. Clean. Prod., 2017, 165, p 1557–1571. https://doi.org/10.1016/J.JCLEPRO.2017.07.23510.1016/J.JCLEPRO.2017.07.235 ↗
2. G. Kshitij, N. Khanna, Ç.V. Yıldırım, S. Dağlı, and M. Sarıkaya, Resource Conservation and Sustainable Development in the Metal Cutting Industry within the Framework of the Green Economy Concept: An Overview and Case Study, Sustain. Mater. Technol., 2022, 34, e00507. https://doi.org/10.1016/J.SUSMAT.2022.E0050710.1016/J.SUSMAT.2022.E00507 ↗
3. S. Zhou et al., Minimum Quantity Lubrication Machining Nickel Base Alloy: A Comprehensive Review, Int. J. Adv. Manuf. Technol., 2023 https://doi.org/10.1007/s00170-023-11721-610.1007/s00170-023-11721-6 ↗
4. T. He et al., Progress and Trend of Minimum Quantity Lubrication (MQL): A Comprehensive Review, J. Clean. Prod., 2023, 386, 135809. https://doi.org/10.1016/J.JCLEPRO.2022.13580910.1016/J.JCLEPRO.2022.135809 ↗
5. K.A. Osman, H.Ö. Ünver, and U. Şeker, Application of Minimum Quantity Lubrication Techniques in Machining Process of Titanium Alloy for Sustainability: A Review, Int. J. Adv. Manuf. Technol., 2019, 100(9–12), p 2311–2332. https://doi.org/10.1007/s00170-018-2813-010.1007/s00170-018-2813-0 ↗
6. Ç.V. Yıldırım, Ş Şirin, T. Kıvak, H. Ercan, and M. Sarıkaya, An Attempt Towards Green Machining of Ni-Based Hastelloy C4 Alloy: Effect of Vegetable Oils and their Combination with TiO2 and SiO2 Nanoparticles on Outputs, Sustain. Mater. Technol., 2023, 37, e00668. https://doi.org/10.1016/J.SUSMAT.2023.E0066810.1016/J.SUSMAT.2023.E00668 ↗
7. R. Bertolini, A. Ghiotti, and S. Bruschi, Graphene Nanoplatelets as Additives to MQL for Improving Tool Life in Machining Inconel 718 Alloy, Wear, 2021, 476, 203656. https://doi.org/10.1016/J.WEAR.2021.20365610.1016/J.WEAR.2021.203656 ↗
8. Ş Şirin, M. Sarıkaya, Ç.V. Yıldırım, and T. Kıvak, Machinability Performance of Nickel Alloy X-750 with SiAlON Ceramic Cutting Tool Under Dry, MQL and hBN Mixed Nanofluid-MQL, Tribol. Int., 2021, 153, 106673. https://doi.org/10.1016/J.TRIBOINT.2020.10667310.1016/J.TRIBOINT.2020.106673 ↗
9. J. Taha-Tijerina, K. Aviña, and J.M. Diabb, Tribological and Thermal Transport Performance of SiO2-Based Natural Lubricants, Lubricants, 2019, 7(8), 71. https://doi.org/10.3390/lubricants708007110.3390/lubricants7080071 ↗
10. S.V. Sujith, A.K. Solanki, and R.S. Mulik, Experimental Evaluation on Rheological Behavior of Al2O3-Pure Coconut Oil Nanofluids, J. Mol. Liq., 2019, 286, 110905. https://doi.org/10.1016/J.MOLLIQ.2019.11090510.1016/J.MOLLIQ.2019.110905 ↗
11. M.A. Makhesana, K.M. Patel, and N. Khanna, Analysis of Vegetable Oil-Based Nano-Lubricant Technique for Improving Machinability of Inconel 690, J. Manuf. Process., 2022, 77, p 708–721. https://doi.org/10.1016/J.JMAPRO.2022.03.06010.1016/J.JMAPRO.2022.03.060 ↗
12. Ş Şirin and T. Kıvak, Performances of Different Eco-Friendly Nanofluid Lubricants in the Milling of Inconel X-750 Superalloy, Tribol. Int., 2019, 137, p 180–192. https://doi.org/10.1016/J.TRIBOINT.2019.04.04210.1016/J.TRIBOINT.2019.04.042 ↗
13. Ç.V. Yıldırım, M. Sarıkaya, T. Kıvak, and Ş Şirin, The Effect of Addition of hBN Nanoparticles to Nanofluid-MQL on Tool Wear Patterns, Tool Life, Roughness and Temperature in Turning of Ni-Based Inconel 625, Tribol. Int., 2019, 134, p 443–456. https://doi.org/10.1016/J.TRIBOINT.2019.02.02710.1016/J.TRIBOINT.2019.02.027 ↗
14. Ş Şirin and T. Kıvak, Effects of Hybrid Nanofluids on Machining Performance in MQL-Milling of Inconel X-750 Superalloy, J. Manuf. Process., 2021, 70, p 163–176. https://doi.org/10.1016/J.JMAPRO.2021.08.03810.1016/J.JMAPRO.2021.08.038 ↗
15. E. Usluer et al., Investigation on the Effect of Hybrid Nanofluid in MQL Condition in Orthogonal Turning and a Sustainability Assessment, Sustain. Mater. Technol., 2023, 36, e00618. https://doi.org/10.1016/J.SUSMAT.2023.E0061810.1016/J.SUSMAT.2023.E00618 ↗
16. N. Khanna, K. Zadafiya, T. Patel, Y. Kaynak, R.A. Rahman Rashid, and A. Vafadar, Review on Machining of Additively Manufactured Nickel and Titanium Alloys, J. Mater. Res. Technol., 2021, 15, p 3192–3221. https://doi.org/10.1016/J.JMRT.2021.09.08810.1016/J.JMRT.2021.09.088 ↗
17. M. Srivastava, S. Rathee, V. Patel, A. Kumar, and P.G. Koppad, A Review of Various Materials for Additive Manufacturing: Recent Trends and Processing Issues, J. Mater. Res. Technol., 2022, 21, p 2612–2641. https://doi.org/10.1016/J.JMRT.2022.10.01510.1016/J.JMRT.2022.10.015 ↗
18. T.D. Ngo, A. Kashani, G. Imbalzano, K.T.Q. Nguyen, and D. Hui, Additive Manufacturing (3D Printing): A Review of Materials, Methods, Applications and Challenges, Compos. B Eng., 2018, 143, p 172–196. https://doi.org/10.1016/J.COMPOSITESB.2018.02.01210.1016/J.COMPOSITESB.2018.02.012 ↗
19. S.I. Shakil, A. Hadadzadeh, B. Shalchi Amirkhiz, H. Pirgazi, M. Mohammadi, and M. Haghshenas, Additive Manufactured Versus Cast AlSi10Mg Alloy: Microstructure and Micromechanics, Res. Mater., 2021, 10, 100178. https://doi.org/10.1016/J.RINMA.2021.10017810.1016/J.RINMA.2021.100178 ↗
20. J. Ding et al., Thermo-Mechanical Analysis of Wire and arc Additive Layer Manufacturing Process on Large Multi-Layer Parts, Comput. Mater. Sci., 2011, 50(12), p 3315–3322. https://doi.org/10.1016/J.COMMATSCI.2011.06.02310.1016/J.COMMATSCI.2011.06.023 ↗
21. T.F. Babuska, B.A. Krick, D.F. Susan, and A.B. Kustas, Comparison of Powder Bed Fusion and Directed Energy Deposition for Tailoring Mechanical Properties of Traditionally Brittle Alloys, Manuf. Lett., 2021, 28, p 30–34. https://doi.org/10.1016/J.MFGLET.2021.02.00310.1016/J.MFGLET.2021.02.003 ↗
22. D. Jafari, T.H.J. Vaneker, and I. Gibson, Wire and Arc Additive Manufacturing: Opportunities and Challenges to Control the Quality and Accuracy of Manufactured Parts, Mater. Des., 2021, 202, 109471. https://doi.org/10.1016/J.MATDES.2021.10947110.1016/J.MATDES.2021.109471 ↗
23. Y. Karabulut and Y. Kaynak, Drilling Process and Resulting Surface Properties of Inconel 718 Alloy Fabricated by Selective Laser Melting Additive Manufacturing, Procedia CIRP, 2020, 87, p 355–359. https://doi.org/10.1016/J.PROCIR.2020.02.11010.1016/J.PROCIR.2020.02.110 ↗
24. L. Chen, Q. Xu, Y. Liu, G. Cai, and J. Liu, Machinability of the Laser Additively Manufactured Inconel 718 Superalloy in Turning, Int. J. Adv. Manuf. Technol., 2021, 114(3–4), p 871–882. https://doi.org/10.1007/s00170-021-06940-810.1007/s00170-021-06940-8 ↗
25. U. Alonso, F. Veiga, A. Suárez, and A. Gil Del Val, Characterization of Inconel 718® Superalloy Fabricated by Wire Arc Additive Manufacturing: Effect on Mechanical Properties and Machinability, J. Mater. Res. Technol., 2021, 14, p 2665–2676. https://doi.org/10.1016/J.JMRT.2021.07.13210.1016/J.JMRT.2021.07.132 ↗
26. P. Raval, D. Patel, R. Prajapati, V. Badheka, M.K. Gupta, and N. Khanna, Energy Consumption and Economic Modelling of Performance Measures in Machining of Wire Arc Additively Manufactured Inconel-625, Sustain. Mater. Technol., 2022, 32, e00434. https://doi.org/10.1016/J.SUSMAT.2022.E0043410.1016/J.SUSMAT.2022.E00434 ↗
27. H. Salvi, H. Vesuwala, P. Raval, V. Badheka, and N. Khanna, Sustainability Analysis of Additive + Subtractive Manufacturing Processes for Inconel 625, Sustain. Mater. Technol., 2023, 35, e00580. https://doi.org/10.1016/J.SUSMAT.2023.E0058010.1016/J.SUSMAT.2023.E00580 ↗
28. N. Khanna, P. Shah, L.N.L. de Lacalle, A. Rodríguez, and O. Pereira, In Pursuit of Sustainable Cutting Fluid Strategy for Machining Ti-6Al-4V Using Life Cycle Analysis, Sustain. Mater. Technol., 2021, 29, e00301. https://doi.org/10.1016/J.SUSMAT.2021.E0030110.1016/J.SUSMAT.2021.E00301 ↗
29. P. Shah, N. Khanna, R.W. Maruda, M.K. Gupta, and G.M. Krolczyk, Life Cycle Assessment to Establish Sustainable Cutting Fluid Strategy for Drilling Ti-6Al-4V, Sustain. Mater. Technol., 2021, 30, e00337. https://doi.org/10.1016/J.SUSMAT.2021.E0033710.1016/J.SUSMAT.2021.E00337 ↗
30. R. Fu et al., Hot-Wire Arc Additive Manufacturing of Aluminum Alloy with Reduced Porosity and High Deposition Rate, Mater. Des., 2021, 199, 109370. https://doi.org/10.1016/J.MATDES.2020.10937010.1016/J.MATDES.2020.109370 ↗
31. G. Huang, G. He, Y. Liu, and K. Huang, Anisotropy of Microstructure, Mechanical Properties and Thermal Expansion in Invar 36 Alloy Fabricated via Laser Powder Bed Fusion, Addit. Manuf., 2024, 82, 104025. https://doi.org/10.1016/J.ADDMA.2024.10402510.1016/J.ADDMA.2024.104025 ↗
32. O.C. Ozaner et al., Dry and Minimum Quantity Lubrication Machining of Additively Manufactured IN718 Produced via Laser Metal Deposition, Lubricants, 2023, 11(12), p 523. https://doi.org/10.3390/lubricants1112052310.3390/lubricants11120523 ↗
33. K. Weinert, I. Inasaki, J.W. Sutherland, and T. Wakabayashi, Dry Machining and Minimum Quantity Lubrication, CIRP Ann., 2004, 53(2), p 511–537. https://doi.org/10.1016/S0007-8506(07)60027-410.1016/S0007-8506(07)60027-4 ↗
34. F. Pusavec, P. Krajnik, and J. Kopac, Transitioning to Sustainable Production – Part I: Application on Machining Technologies, J. Clean. Prod., 2010, 18(2), p 174–184. https://doi.org/10.1016/J.JCLEPRO.2009.08.01010.1016/J.JCLEPRO.2009.08.010 ↗
35. S.G. Chetan and P. Venkateswara Rao, Application of Sustainable Techniques in Metal Cutting for Enhanced Machinability: A Review, J. Clean. Prod., 2015, 100, p 17–34. https://doi.org/10.1016/J.JCLEPRO.2015.03.03910.1016/J.JCLEPRO.2015.03.039 ↗
36. V.S. Sharma, G. Singh, and K. Sørby, A Review on Minimum Quantity Lubrication for Machining Processes, Mater. Manuf. Process., 2015, 30(8), p 935–953. https://doi.org/10.1080/10426914.2014.99475910.1080/10426914.2014.994759 ↗
37. E.A. Rahim and H. Dorairaju, Evaluation of Mist Flow Characteristic and Performance in Minimum Quantity Lubrication (MQL) Machining, Measurement, 2018, 123, p 213–225. https://doi.org/10.1016/J.MEASUREMENT.2018.03.01510.1016/J.MEASUREMENT.2018.03.015 ↗
38. M.R. Vazirisereshk, A. Martini, D.A. Strubbe, and M.Z. Baykara, Solid Lubrication with MoS2: A Review, Lubricants, 2019, 7(7), 57. https://doi.org/10.3390/lubricants707005710.3390/lubricants7070057 ↗
39. Y.J.J. Jason, H.G. How, Y.H. Teoh, and H.G. Chuah, A Study on the Tribological Performance of Nanolubricants, Processes, 2020, 8(11), 1372. https://doi.org/10.3390/pr811137210.3390/pr8111372 ↗
40. B. Jin, G. Chen, J. Zhao, Y. He, Y. Li, and J. Luo, Coupling Effect of Boundary Tribofilm and Hydrodynamic Film, Cell Rep. Phys. Sci., 2022, 3(3), 100778. https://doi.org/10.1016/j.xcrp.2022.10077810.1016/j.xcrp.2022.100778 ↗
41. Ç.V. Yıldırım, Ş Şirin, T. Kıvak, and M. Sarıkaya, A Comparative Study on the Tribological Behavior of Mono & Proportional Hybrid Nanofluids for Sustainable Turning of AISI 420 Hardened Steel with Cermet Tools, J. Manuf. Process., 2022, 73, p 695–714. https://doi.org/10.1016/J.JMAPRO.2021.11.04410.1016/J.JMAPRO.2021.11.044 ↗
42. X. Zhang et al., Vegetable Oil-Based Nanolubricants in Machining: From Physicochemical Properties to Application, Chin. J. Mech. Eng., 2023, 36(1), 76. https://doi.org/10.1186/s10033-023-00895-510.1186/s10033-023-00895-5 ↗
43. S. Chinchanikar, S.S. Kore, and P. Hujare, A Review on Nanofluids in Minimum Quantity Lubrication Machining, J. Manuf. Process., 2021, 68, p 56–70. https://doi.org/10.1016/J.JMAPRO.2021.05.02810.1016/J.JMAPRO.2021.05.028 ↗
44. P. Shah, P. Bhat, and N. Khanna, Life Cycle Assessment of Drilling Inconel 718 Using Cryogenic Cutting Fluids While Considering Sustainability Parameters, Sustain. Energy Technol. Assess., 2021, 43, 100950. https://doi.org/10.1016/J.SETA.2020.10095010.1016/J.SETA.2020.100950 ↗
45. S. Sujai and K. Devendranath Ramkumar, Microstructure and Mechanical Characterization of Incoloy 925 Welds in the As-Welded and Direct Aged Conditions, J. Mater. Eng. Perform., 2019, 28(3), p 1563–1580. https://doi.org/10.1007/s11665-019-03960-010.1007/s11665-019-03960-0 ↗
46. D. Ding, Z. Pan, D. Cuiuri, and H. Li, Wire-feed Additive Manufacturing of Metal Components: Technologies, Developments and Future Interests, Int. J. Adv. Manuf. Technol., 2015, 81(1–4), p 465–481. https://doi.org/10.1007/s00170-015-7077-310.1007/s00170-015-7077-3 ↗
47. F. Martina, J. Mehnen, S.W. Williams, P. Colegrove, and F. Wang, Investigation of the Benefits of Plasma Deposition for the Additive Layer Manufacture of Ti–6Al–4V, J. Mater. Process. Technol., 2012, 212(6), p 1377–1386. https://doi.org/10.1016/j.jmatprotec.2012.02.00210.1016/j.jmatprotec.2012.02.002 ↗
48. N. Khanna et al., Comparison of Dry and Liquid Carbon Dioxide Cutting Conditions Based on Machining Performance and Life Cycle Assessment for End Milling GFRP, Int. J. Adv. Manuf. Technol., 2022, 122(2), p 821–833. https://doi.org/10.1007/s00170-022-09843-410.1007/s00170-022-09843-4 ↗
49. N. Khanna, C. Agrawal, M. Dogra, and C.I. Pruncu, Evaluation of Tool Wear, Energy Consumption, and Surface Roughness During Turning of Inconel 718 Using Sustainable Machining Technique, J. Mater. Res. Technol., 2020, 9(3), p 5794–5804. https://doi.org/10.1016/J.JMRT.2020.03.10410.1016/J.JMRT.2020.03.104 ↗
50. V.T. Le, H. Paris, and G. Mandil, Environmental Impact Assessment of an Innovative Strategy Based on an Additive and Subtractive Manufacturing Combination, J. Clean. Prod., 2017, 164, p 508–523. https://doi.org/10.1016/J.JCLEPRO.2017.06.20410.1016/J.JCLEPRO.2017.06.204 ↗
51. A. Kapil et al., Overcoming Machining Challenges in Hybrid Laser Metal Deposition of IN718 with Heat-Assisted Minimum Quantity Lubrication, Int. J. Adv. Manuf. Technol., 2024, 132(11–12), p 5407–5424. https://doi.org/10.1007/s00170-024-13646-010.1007/s00170-024-13646-0 ↗
52. N. Talib and E.A. Rahim, Performance of Modified Jatropha Oil in Combination with Hexagonal Boron Nitride Particles as a Bio-Based Lubricant for Green Machining, Tribol. Int., 2018, 118, p 89–104. https://doi.org/10.1016/J.TRIBOINT.2017.09.01610.1016/J.TRIBOINT.2017.09.016 ↗
53. Z. Gao, H. Zhang, M. Ji, C. Zuo, and J. Zhang, Influence of Various Cooling and Lubrication Conditions on Tool Wear and Machining Quality in Milling Inconel 718, Int. J. Precis. Eng. Manuf. Green Technol., 2023 https://doi.org/10.1007/s40684-023-00558-910.1007/s40684-023-00558-9 ↗
54. H. Hegab, U. Umer, I. Deiab, and H. Kishawy, Performance Evaluation of Ti–6Al–4V Machining Using Nano-Cutting Fluids Under Minimum Quantity Lubrication, Int. J. Adv. Manuf. Technol., 2018, 95(9–12), p 4229–4241. https://doi.org/10.1007/s00170-017-1527-z10.1007/s00170-017-1527-z ↗
55. A.K. Sharma, J.K. Katiyar, S. Bhaumik, and S. Roy, Influence of Alumina/MWCNT Hybrid Nanoparticle Additives on Tribological Properties of Lubricants in Turning Operations, Friction, 2019, 7(2), p 153–168. https://doi.org/10.1007/s40544-018-0199-510.1007/s40544-018-0199-5 ↗
56. J. He, J. Sun, Y. Meng, and X. Yan, Preliminary Investigations on the Tribological Performance of Hexagonal Boron Nitride Nanofluids as Lubricant for Steel/Steel Friction Pairs, Surf Topogr, 2019, 7(1), 015022. https://doi.org/10.1088/2051-672X/ab0afb10.1088/2051-672X/ab0afb ↗
57. C.J. Reeves, P.L. Menezes, M.R. Lovell, and T.-C. Jen, The Size Effect of Boron Nitride Particles on the Tribological Performance of Biolubricants for Energy Conservation and Sustainability, Tribol. Lett., 2013, 51(3), p 437–452. https://doi.org/10.1007/s11249-013-0182-210.1007/s11249-013-0182-2 ↗
58. E. Şirin, T. Kıvak, and Ç.V. Yıldırım, Effects of Mono/Hybrid Nanofluid Strategies and Surfactants on Machining Performance in the Drilling of Hastelloy X, Tribol. Int., 2021, 157, 106894. https://doi.org/10.1016/J.TRIBOINT.2021.10689410.1016/J.TRIBOINT.2021.106894 ↗
59. M. Vardhanapu, P.K. Chaganti, and P. Tarigopula, Characterization and Machine Learning-Based Parameter Estimation in MQL Machining of a Superalloy for Developed Green Nano-Metalworking Fluids, J. Braz. Soc. Mech. Sci. Eng., 2023, 45(3), 154. https://doi.org/10.1007/s40430-023-04078-010.1007/s40430-023-04078-0 ↗
60. E. Brinksmeier, D. Meyer, A.G. Huesmann-Cordes, and C. Herrmann, Metalworking Fluids—Mechanisms and Performance, CIRP Ann., 2015, 64(2), p 605–628. https://doi.org/10.1016/J.CIRP.2015.05.00310.1016/J.CIRP.2015.05.003 ↗
61. V.S. Sharma, M. Dogra, and N.M. Suri, Cooling Techniques for Improved Productivity in Turning, Int. J. Mach. Tools Manuf, 2009, 49(6), p 435–453. https://doi.org/10.1016/J.IJMACHTOOLS.2008.12.01010.1016/J.IJMACHTOOLS.2008.12.010 ↗
62. H. Singh, V.S. Sharma, and M. Dogra, Exploration of Graphene Assisted Vegetables Oil Based Minimum Quantity Lubrication for Surface Grinding of TI-6AL-4V-ELI, Tribol. Int., 2020, 144, 106113. https://doi.org/10.1016/J.TRIBOINT.2019.10611310.1016/J.TRIBOINT.2019.106113 ↗