Comparative Environmental Impact Analysis of Friction-based Additive Manufacturing Techniques

In this work, two variants of solid-state friction-based additive processes, Friction Surfacing Deposition and Friction Stir Additive Manufacturing, were compared in terms of their environmental impact. A comparative Life Cycle Assessment analysis was performed, alongside experimental quantification and analysis of energy and resource flows for each process. The energy analysis revealed that the friction stir additive manufacturing is a more energy-consuming technology than surfacing process due to the significantly lower tool feed rate required to produce sound welds. It was determined that the most significant contributor to the environmental impact of both methods is the process scrap. Strategies to reduce material waste were proposed for each technology, tailored to the specific characteristics of their implementation. Furthermore, an additional LCA model was developed to evaluate strategies for minimizing FSAM process scrap.