Environmental assessment of laser assisted manufacturing: case studies on laser shock peening and laser assisted turning

Laser assisted manufacturing processes, when compared with traditional manufacturing processes, have the potential to reduce cost, increase surface resistance to wear and fatigue, extend part/tool life, and expand the range of manufacturable materials. These processes have found niche applications in automotive, aerospace, and defense industries. However, very limited research has been conducted to evaluate and compare the environmental performance of laser assisted processes with traditional methods. This paper conducts case studies on two representative laser based processes, i.e. laser shock peening of 7075-T7351 Aluminum and laser assisted turning of compacted graphite iron. Life cycle assessment is used to benchmark the environmental performance of these two processes to conventional processes, i.e. shot peening and turning, respectively. The life cycle inventory of both the laser based processes and conventional processes are developed using SimaPro 7.1 and the Ecoinvent 2.0 database and life cycle impact assessment is performed using US EPA TRACI. The results of this study show that the environmental performance of the two laser based processes is significantly better than conventional processes. For laser shock peening of aluminum, contribution analysis indicates that this is mainly due to the significant extension of fatigue life of the workpiece being treated. For laser assisted turning of compacted graphite iron, the improved performance is mainly due to the extended tool life since cutting tool manufacturing is an energy intensive process. Development of high-power laser with a lower wavelength (e.g. direct diode system) could eliminate the use of paint in laser assisted turning. This, along with improved wall plug efficiency, makes laser assisted turning even more environmentally benign compared to conventional process. A brief cost analysis suggests that both laser shock peening and laser assisted turning can be economically viable with payback period less than three years for niche applications.