Sustainability in manufacturing processes: practices performed in metal forming, casting, heat treatment, welding and electrostatic painting

ABSTRACT This article aims to list the main sustainable practices developed in the processes of metal forming, casting, heat treatment, welding and electrostatic painting. When analysed the literature about sustainable manufacturing, a predominance of studies about machining is observed and the processes mentioned are few explored in academic studies. The research strategy used to reach the objective was systematic literature review, conducted for each process cited. Many sustainable practices were identified with prominence of better materials use and energy efficiency. The authors of this article believe that the information presented here can be useful for researches in their future studies and for industry professionals interested in improving manufacturing processes.

[1]  Michael Zwicky Hauschild,et al.  Drivers and barriers for implementation of environmental strategies in manufacturing companies , 2013 .

[2]  Pardeep Kumar,et al.  Waste foundry sand in concrete: A review , 2017 .

[3]  A. Jullien,et al.  Recycling foundry sand in road construction–field assessment , 2014 .

[4]  S. Balasubramanian,et al.  Lasers in Green Manufacturing Processes , 2014 .

[5]  Carolien Kroeze,et al.  Strategies to reduce the environmental impact of an aluminium pressure die casting plant: a scenario analysis. , 2009, Journal of environmental management.

[6]  Steffen Bonss,et al.  Laser beam hardening – Energy efficient heat treatment? , 2009 .

[7]  Ross Gagliano,et al.  Review of , 2006, UBIQ.

[8]  V. Meshalkin,et al.  Multicriterial optimization of the energy efficiency of the thermal preparation of raw materials , 2015, Theoretical Foundations of Chemical Engineering.

[9]  S. Vinodh,et al.  Modelling, assessment and deployment of strategies for ensuring sustainable shielded metal arc welding process – a case study , 2015 .

[10]  J. Antonini,et al.  Health Effects of Welding , 2003, Critical reviews in toxicology.

[11]  S. Sivapirakasam,et al.  Welding fume reduction by nano-alumina coating on electrodes – towards green welding process , 2015 .

[12]  Aldona Kluczek,et al.  Application of best available techniques in an enterprise producing heating devices , 2014 .

[13]  P. Mehrani,et al.  Impact of Addition of a Catalyst or Its Support on Reactor Wall Coating Due to Electrostatic Charging during Fluidization of Polyethylene , 2015 .

[14]  L. K. Toke,et al.  A framework of enabler’s relationship for implementation of green manufacturing in Indian context , 2018 .

[15]  Desh Paul Mehta Energy Efficiency through Waste Heat Recovery in Automotive Manufacturing Related Industries , 2011 .

[16]  Konstantinos Salonitis,et al.  Improvements in energy consumption and environmental impact by novel single shot melting process for casting , 2016 .

[17]  N. Kashaev,et al.  Investigating the impact of sustainability in the production of aeronautical subscale components , 2018 .

[18]  Konstantinos Salonitis,et al.  Simulation Based Energy and Resource Efficient Casting Process Chain Selection: A Case Study , 2017 .

[19]  Giuseppe Ingarao,et al.  Subtractive versus mass conserving metal shaping technologies: an environmental impact comparison , 2015 .

[20]  A. Remmen,et al.  Life cycle assessment for printed newspapers in Northwestern Mexico , 2015 .

[21]  Markus A. Reuter,et al.  CFD prediction for the performance of a heat treatment furnace , 2007 .

[22]  A. Klaus,et al.  Manufacturing of Lightweight Components by Metal Forming , 2003 .

[23]  Marco Noro,et al.  Energy efficiency opportunities in the production process of cast iron foundries: An experience in Italy , 2015 .

[24]  Pontus Berg Energy Management in Heat Treatment , 2014 .

[25]  Shubham,et al.  Organizational adoption of sustainable manufacturing practices in India: integrating institutional theory and corporate environmental responsibility , 2018 .

[26]  D. Granatstein,et al.  Sustainable Horticulture in Fruit Production , 2008 .

[27]  C. Ohlson,et al.  Airways symptoms, immunological response and exposure in powder painting , 2005, International archives of occupational and environmental health.

[28]  Vladimir Velichkin,et al.  Optimization of Thermal Object Nonlinear Control Systems by Energy Efficiency Criterion. , 2018 .

[29]  Zhrgang Wang,et al.  Tribological approaches for green metal forming , 2004 .

[30]  Ali Hasanbeigi,et al.  Alternative emerging ironmaking technologies for energy-efficiency and carbon dioxide emissions reduction: A technical review , 2014 .

[31]  Améziane Aoussat,et al.  Systematic literature review of eco-innovation models: Opportunities and recommendations for future research , 2017 .

[33]  J. B. Roberts,et al.  Reducing Solvent Emissions in Automotive Spray Painting , 1976 .

[34]  Lucienne Blessing,et al.  Sustainability in manufacturing: Recovery of resources in product and material cycles , 2007 .

[35]  Duck Bong Kim,et al.  A decision-guidance framework for sustainability performance analysis of manufacturing processes , 2014 .

[36]  Kuldip Singh Sangwan,et al.  Development of a multi criteria decision model for justification of green manufacturing systems , 2011 .

[37]  Torgeir Welo,et al.  A Holistic approach to corporate sustainability assessment: Incorporating sustainable development goals into sustainable manufacturing performance evaluation , 2019, Journal of Manufacturing Systems.

[38]  Konstantinos Salonitis,et al.  The challenges for energy efficient casting processes , 2016 .

[39]  S. Button,et al.  Conformacao plastica dos metais , 1991 .

[40]  Fu Zhao,et al.  Econological scheduling of a manufacturing enterprise operating under a time-of-use electricity tariff , 2015 .

[41]  Timothy G. Gutowski,et al.  The energy requirements and environmental impacts of sheet metal forming: An analysis of five forming processes , 2017 .

[42]  J. D. Wang,et al.  Acute and chronic neurological symptoms among paint workers exposed to mixtures of organic solvents. , 1993, Environmental research.

[43]  R. Valente,et al.  Blank optimization in a stamping process-Influence of the geometry definition , 2012 .

[44]  Hakan Fridén,et al.  Energy Efficiency Optimisation in Heat Treatment Process Design , 2012, APMS.

[45]  R. KrishnaRaj,et al.  Foundry Air Pollution: Hazards, Measurements and Control , 2015 .

[46]  Bo Fu,et al.  Virtualized welding based teleoperation with pipe gas tungsten arc welding applications , 2014, 2014 IEEE/ASME International Conference on Advanced Intelligent Mechatronics.

[47]  Kozo Saito,et al.  Effects of automotive paint spray technology on the paint transfer efficiency – a review , 2018 .

[48]  Giuseppe Ingarao,et al.  Sustainability issues in sheet metal forming processes: an overview , 2011 .

[49]  Chen Xiaomeng,et al.  Billets Heat Treatment using Flue Gas for Energy Efficiency and Batching Cycle Time Reduction , 2017 .

[50]  Takashi Irohara,et al.  Scheduling for sustainable manufacturing: A review , 2018, Journal of Cleaner Production.

[51]  Michele Germani,et al.  Review of ecodesign methods and tools. Barriers and strategies for an effective implementation in industrial companies , 2016 .

[52]  Xiaoxiang Shi,et al.  A new approach of die shape optimization for sheet metal forming processes , 2004 .

[53]  S. Al-Athel,et al.  Report of the World Commission on Environment and Development: "Our Common Future" , 1987 .

[54]  Fangyi Li,et al.  A review on the recent development of incremental sheet-forming process , 2017 .

[55]  L. O. Cezarino,et al.  Strategy for sustainability in a Brazilian sugarcane industry , 2014 .

[56]  Erwin Rauch,et al.  Sustainability in Manufacturing through Distributed Manufacturing Systems (DMS) , 2015 .

[57]  W. Filho,et al.  Implementation of cleaner production: A ten-year retrospective on benefits and difficulties found , 2018, Journal of Cleaner Production.

[59]  Keshav Valase,et al.  Mediation analysis of multiple constructs in the relationship between manufacturing and technology and environmental constructs in structural equation model for sustainable manufacturing , 2018, The International Journal of Advanced Manufacturing Technology.

[60]  Jatinder Madan,et al.  A computer-aided system for sustainability assessment for the die-casting process planning , 2013, The International Journal of Advanced Manufacturing Technology.

[61]  Numerical investigation on post-combustion in a burner for heat treatment furnaces with a reducing gas atmosphere , 2017 .

[62]  G. Totten,et al.  Comparison of structure and quenching performance of vegetable oils. , 2009 .

[63]  S. Kyrtopoulos,et al.  Molecular epidemiological approaches to the study of the genotoxic effects of urban air pollution. , 1999, Mutation research.

[64]  Kuldip Singh Sangwan,et al.  Development of a structural model of environmentally conscious manufacturing drivers , 2014 .

[65]  Andres F. Clarens,et al.  A Review of Engineering Research in Sustainable Manufacturing , 2013 .

[66]  Gaurav D. Sonawane,et al.  Review on Recent Trends & Optimisation in Heat Treatment , 2014 .

[67]  Taylan Altan,et al.  Sheet metal forming at elevated temperatures , 2006 .

[68]  Hiroyuki Matsuura,et al.  Slag Foaming in an Electric Arc Furnace , 2009 .

[69]  Howard E. Boyer,et al.  Practical Heat Treating , 1984 .

[70]  Konstantinos Salonitis,et al.  The Development of a Tool to Promote Sustainability in Casting Processes , 2016 .

[71]  David E. Hardt,et al.  Design and analysis of reconfigurable discrete dies for sheet metal forming , 1998 .

[72]  B. Moen,et al.  Reduced exposure to organic solvents by use of water-based paint systems in car repair shops , 2004, International archives of occupational and environmental health.

[73]  Permanent Molding of Cast Irons – Present Status and Scope , 2012 .

[74]  Matthias Finkbeiner,et al.  Environmental and Social Life Cycle Assessment of Welding Technologies , 2015 .

[75]  M. Taisch,et al.  Sustainable manufacturing: trends and research challenges , 2012 .

[76]  H. E. Boyer,et al.  Practical Heat Treating: Second Edition , 2006 .

[77]  Xiaowei Pan,et al.  Energy improvement in induction furnace using foaming slag with variation of carbon injection , 2017 .

[78]  Arul Arulrajah,et al.  Recycled waste foundry sand as a sustainable subgrade fill and pipe-bedding construction material: Engineering and environmental evaluation , 2017 .

[79]  Fazleena Badurdeen,et al.  Strategies for Value Creation Through Sustainable Manufacturing , 2017 .

[80]  Mohammad Habibi Parsa,et al.  Optimization of initial blank shape predicted based on inverse finite element method , 2007 .

[81]  Structural Steels,et al.  Welding Metallurgy of , 1987 .

[82]  Marion Merklein,et al.  A review on tailored blanks—Production, applications and evaluation , 2014 .

[83]  Young Hoon Moon,et al.  Manufacturing of tailor-rolled blanks with thickness variations in both the longitudinal and latitudinal directions , 2018, Journal of Materials Processing Technology.

[84]  Hasan Habibul Latf Sustainability index development for manufacturing industry , 2017 .

[85]  John M. Haake,et al.  Heat treating and cladding operations with high-power diode lasers , 2005, SPIE LASE.

[86]  Michael Zwicky Hauschild,et al.  From Life Cycle Assessment to Sustainable Production: Status and Perspectives , 2005 .

[87]  John M. Papazian,et al.  Design and Test of a Reconfigurable Forming Die , 2002 .

[88]  Devkumar S. Callychurn,et al.  Developing a sustainability index for Mauritian manufacturing companies , 2019, Ecological Indicators.

[89]  Franziska Müller Sustainable Development Goals (SDGs) , 2015 .

[90]  William D. Callister,et al.  Materials Science and Engineering: An Introduction , 1985 .

[91]  A. Gunasekaran,et al.  Factors for implementing end-of-life product reverse logistics in the Chinese manufacturing sector , 2014 .

[92]  Andreas Kugi,et al.  Energy-Efficient Control of Continuous Reheating Furnaces , 2013 .

[93]  Licentiate Thesis Material Modelling for Simulation of Heat Treatment , 2003 .

[94]  Konstantinos Salonitis,et al.  Manufacturing Cost Modeling of Castings Produced with CRIMSON Process , 2014 .

[95]  Malin Källen Energy Efficiency Opportunities within the Heat Treatment Industry , 2012 .

[96]  Peter Krajnik,et al.  Transitioning to sustainable production – Part I: application on machining technologies , 2010 .

[98]  Gurpreet Singh,et al.  Effect of waste foundry sand (WFS) as partial replacement of sand on the strength, ultrasonic pulse velocity and permeability of concrete , 2012 .

[99]  Jozsef Boer,et al.  Optimizing Production Costs by Redesigning the Treatment Process of the Industrial Waste Water , 2016 .

[100]  M. Thenarasu,et al.  Evaluation of Mechanical Properties, Economic and Environmental Benefits of Partially Replacing Silica Sand with Biomass Ash for Aluminium Casting , 2018 .

[101]  Taylan Altan,et al.  Mechanical servo press technology for metal forming , 2011 .

[102]  Giuseppe Ingarao,et al.  A sustainability point of view on sheet metal forming operations: material wasting and energy consumption in incremental forming and stamping processes , 2012 .

[103]  Wided Guédria,et al.  Interoperability assessment: A systematic literature review , 2019, Comput. Ind..

[104]  D. Tranfield,et al.  Producing a systematic review. , 2009 .

[105]  Aldo Roberto Ometto,et al.  Theoretical contribution of industrial ecology to circular economy , 2018 .

[106]  I. D. Paul,et al.  A Review on Green Manufacturing: It's Important, Methodology and its Application☆ , 2014 .

[107]  Salim Belouettar,et al.  A numerical method for the optimal blank shape design , 2011 .

[108]  Adil Baykasoğlu,et al.  Dynamic scheduling of parallel heat treatment furnaces: A case study at a manufacturing system , 2018 .