A Comparative Experimental Research on Economic and Environmental Performance and Mechanical Properties of Additive Friction Stir Deposition

Additive Friction Stir Deposition (AFSD) is a relatively new solid-state additive manufacturing technology with significant advantages in terms of high deposition rates and superior part quality. These features enable the application of this technology to different fields and numerous purposes. Recognizing the potential of a hybrid approach to simultaneously reduce material consumption and maintain good performance, the study addresses the lack of research in this area. This investigation addresses this research gap by conducting a comprehensive comparison between a part manufactured by AFSD followed with finishing by CNC machining (hybrid), and another one produced purely by the subtractive process of CNC machining solely. Utilizing a cradle-to-gate Life Cycle Assessment for environmental evaluation and an economic model accounting for machine cost, material cost, electricity expenses, and labor costs, the research provides a thorough analysis of producing parts using hybrid and subtractive approaches. All data for the LCA and economic assessment are directly measured during the manufacturing of components, made from Aluminum (AA 6061). Data is gathered to produce a total of four components, identical in design but differing in size, through both processes. Components of different sizes are fabricated to investigate any potential impact of size variation on economic and environmental performance. In addition, the mechanical properties of the components are investigated to provide a comprehensive comparison. The study seeks to offer valuable insights into the benefits and trade-offs associated with each manufacturing approach, contributing to more informed decision-making in advanced manufacturing and material processing. The findings will illuminate the environmental sustainability and economic feasibility of the hybrid AFSD and CNC machining process, guiding future practices in the evolving landscape of advanced manufacturing.