Title
Design optimisation for hybrid metal additive manufacturing for sustainable construction
Author
Baqershahi, Mohammad Hassan (Leibniz Universität)
Ayas, C. (TU Delft Computational Design and Mechanics)
Ghafoori, Elyas (Leibniz Universität)
Date
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.
Subject
Design for sustainability
Environmental assessment
Hybrid manufacturing
Metal additive manufacturing
Topology optimisation
To reference this document use:
http://resolver.tudelft.nl/uuid:cbc8e62f-0959-4ca6-9d42-bdb2af00c88c
DOI
https://doi.org/10.1016/j.engstruct.2023.117355
Embargo date
2024-06-21
ISSN
0141-0296
Source
Engineering Structures, 301
Bibliographical note
Green Open Access added to TU Delft Institutional Repository 'You share, we take care!' - Taverne project https://www.openaccess.nl/en/you-share-we-take-care Otherwise as indicated in the copyright section: the publisher is the copyright holder of this work and the author uses the Dutch legislation to make this work public.
Part of collection
Institutional Repository
Document type
journal article
Rights
© 2024 Mohammad Hassan Baqershahi, C. Ayas, Elyas Ghafoori