EXTENDING COMPONENT LIFE THROUGH HYBRID ADDITIVE MANUFACTURING: ENVIRONMENTAL ASSESSMENT OF A REMANUFACTURED VALVE COMPONENT

Sepideh GHOLAMZADEH, Mattia CABRIOLI, Matteo VANAZZI, Alex GIORGINI, Daniele BRAMBILLA, Gianluca ACQUISTAPACE, Matteo PERINI, Sasan AMIRABDOLLAHIAN

Abstract


This study evaluates the environmental benefits of extending the life of industrial parts through hybrid additive manufacturing instead of full replacement. A case study involved modifying an LF2 carbon steel ball valve flange using Laser Directed Energy Deposition (LDED) with recycled 316L stainless steel powder. The process included CNC milling, metal deposition, and precision machining. Non-destructive and pressure tests confirmed the mechanical integrity and performance of the remanufactured component. A Life Cycle Assessment compared this approach with conventional replacement, showing significant reductions in raw material use, energy consumption, and CO₂ emissions. The results highlight hybrid manufacturing as a sustainable solution aligned with circular economy goals, promoting reuse and minimizing environmental impact without compromising functionality.

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