Economic and Environmental Sustainability Performance of Additive Friction Stir Deposition: A Comparative Analysis

Additive Friction Stir Deposition (AFSD) is a relatively new solid-state additive manufacturing technology showing significant advantages in high deposition rates and superior part quality. These features enable the application of this technology to different fields and numerous purposes. The present study addresses the lack of research related to the sustainability performance of AFSD. For this purpose, a comprehensive comparison between parts manufactured by AFSD followed with finishing by CNC machining (hybrid) and another produced purely by the subtractive process is carried out, specifically focusing on their environmental and economic impacts. Using a cradle-to-gate Life Cycle Assessment (LCA) for environmental evaluation and an economic model accounting for machining, material, electricity, and labor costs, the research analyses producing parts using the hybrid and subtractive processes. All the data for the LCA and economic assessment are directly measured during the manufacturing of AA 6061 Aluminum alloy components. Data is gathered while manufacturing four components, identical in design but different in size, to investigate the potential impacts of size variation on economic and environmental performance. The study offers valuable insights into the benefits and trade-offs associated with the investigated manufacturing approaches, contributing to more informed decision-making in advanced manufacturing and material processing. The findings will provide insights on the environmental sustainability and economic benefits of the hybrid AFSD-CNC machining process, guiding future practices in the evolving landscape of advanced manufacturing.