Daniel Elduque

The Influence of Different Recycling Scenarios on the Mechanical Design of an LED Weatherproof Light Fitting

This paper analyzes the high relevance of material selection for the sustainable development of an LED weatherproof light fitting. The research reveals how this choice modifies current and future end of life scenarios and can reduce the overall environmental impact. This life cycle assessment has been carried out with Ecotool, a software program especially developed for designers to assess the environmental performance of their designs at the same time that they are working on them. Results show that special attention can be put on the recycling and reusing of the product from the initial stages of development.

Influence of composition on the environmental impact of a cast aluminum alloy

The influence of alloy composition on the environmental impact of the production of six aluminum casting alloys (Al Si12Cu1(Fe), Al Si5Mg, Al Si9Cu3Zn3Fe, Al Si10Mg(Fe), Al Si9Cu3(Fe)(Zn) and Al Si9) has been analyzed. In order to perform a more precise environmental impact calculation, Life Cycle Assessment (LCA) with ReCiPe Endpoint methodology has been used, with the EcoInvent v3 AlMg3 aluminum alloy dataset as a reference. This dataset has been updated with the material composition ranges of the mentioned alloys. The balanced, maximum and minimum environmental impact values have been obtained. In general, the overall impact of the studied aluminum alloys varies from 5.98 × 10−1 pts to 1.09 pts per kg, depending on the alloy composition. In the analysis of maximum and minimum environmental impact, the alloy that has the highest uncertainty is AlSi9Cu3(Fe)(Zn), with a range of ±9%. The elements that contribute the most to increase its impact are Copper and Tin. The environmental impact of a specific case, an LED luminaire housing made out of an Al Si12Cu1(Fe) cast alloy, has been studied, showing the importance of considering the composition. Significant differences with the standard datasets that are currently available in EcoInvent v3 have been found.

A systematic material selection process applied to a luminaire diffuser

This paper presents a systematic material selection process for technical, environmental and economic criteria. This methodology has been applied to the design of a weatherproof luminaire. The materials selected for the production of this diffuser were characterised to obtain their mechanical properties and to perform exhaustive research on impact analysis by means of finite element modelling. Also an economic analysis and an ecological impact assessment have been performed. Thanks to this working methodology, a final design of the diffuser has been developed having the optimum thickness to achieve the mechanical specifications and minimise the environmental impact and the cost of the diffuser.

Analysis of the Influence of Microcellular Injection Molding on the Environmental Impact of an Industrial Component

Microcellular injection molding is a process that offers numerous benefits due to the internal structure generated; thus, many applications are currently being developed in different fields, especially home appliances. In spite of the advantages, when changing the manufacturing process from conventional to microcellular injection molding, it is necessary to analyze its new mechanical properties and the environmental impact of the component. This paper presents a deep study of the environmental behavior of a manufactured component by both conventional and microcellular injection molding. Environmental impact will be evaluated performing a life cycle assessment. Functionality of the component will be also evaluated with samples obtained from manufactured components, to make sure that the mechanical requirements are fulfilled when using microcellular injection molding. For this purpose a special device has been developed to measure the flexural modulus. With a 16% weight reduction, the variation of flexural properties in the microcellular injected components is only 6.8%. Although the energy consumption of the microcellular injection process slightly increases, there is an overall reduction of the environmental burden of 14.9% in ReCiPe and 15% in carbon footprint. Therefore, MuCell technology can be considered as a green manufacturing technology for components working mainly under flexural load.

Methodology to Analyze the Influence of Microcellular Injection Molding on Mechanical Properties with Samples Obtained Directly of An Industrial Component

Microcellular injection molding is a process that offers numerous benefits thanks to the internal structure generated, thus many applications are being arising in different fields, especially home appliance. In spite of it, when changing the manufacturing process of a component from conventional injection molding to microcellular injection molding, it is necessary to ensure the mechanical properties of the component. In this paper a study of the mechanical behavior of samples obtained directly from a manufactured component both by conventional injection molding and microcellular injection molding is carried out. This kind of samples take into account the process conditions under the final component is processed and the influence of these conditions on the mechanical properties. For this purpose special devices have been developed taking into account the characteristics of the component and the samples obtained. An X-ray 3D computed tomography is also carried out to validate the internal structure of the microcellular injection molded component. Tensile properties are reduced between 20–22% regarding flow direction when using microcellular injection molding. Impact properties are reduced up to 27%. However, flexural properties reduction for samples processed by microcellular injection is only 6.8%, so microcellular injection molding arises as a very suitable process for components working under this kind of load. Molding and impact tests are carried out by using specially developed devices.

Visco-Hyperelastic Model with Damage for Simulating Cyclic Thermoplastic Elastomers Behavior Applied to an Industrial Component

In this work a nonlinear phenomenological visco-hyperelastic model including damage consideration is developed to simulate the behavior of Santoprene 101-73 material. This type of elastomeric material is widely used in the automotive and aeronautic sectors, as it has multiple advantages. However, there are still challenges in properly analyzing the mechanical phenomena that these materials exhibit. To simulate this kind of material a lot of theories have been exposed, but none of them have been endorsed unanimously. In this paper, a new model is presented based on the literature, and on experimental data. The test samples were extracted from an air intake duct component of an automotive engine. Inelastic phenomena such as hyperelasticity, viscoelasticity and damage are considered singularly in this model, thus modifying and improving some relevant models found in the literature. Optimization algorithms were used to find out the model parameter values that lead to the best fit of the experimental curves from the tests. An adequate fitting was obtained for the experimental results of a cyclic uniaxial loading of Santoprene 101-73.

Influence of the Composition on the Environmental Impact of Soft Ferrites

The aim of this paper is to analyze the influence of the composition on the environmental impact of the two main types of soft ferrites, allowing scientists and engineers to compare them based not only on cost and properties, but also on an environmental point of view. Iron oxides are the basis of soft ferrites, but these ferrites have a wide range of compositions, using materials such as manganese or nickel, which affect their magnetic properties, but also modify the environmental impact. A Life Cycle Assessment has been carried out for manganese‒zinc (MnZn) and nickel‒zinc (NiZn) soft ferrites, with a Monte Carlo approach to assess multiple compositions. The LCA model was developed with SimaPro 8.4, using the EcoInvent v3.4 life cycle inventory database. Environmental impact values were calculated under the ReCiPe and Carbon Footprint methodologies, obtaining a broad variety of results depending on the composition. The results were also significantly different from the standard EcoInvent ferrite. For the analyzed soft ferrites, the presence of manganese or nickel is a key factor from an environmental perspective, as these materials involve high environmental impacts, and their supply risk has increased during recent years, making them a concern for European manufacturers.

Electricity Consumption Estimation of the Polymer Material Injection-Molding Manufacturing Process: Empirical Model and Application

Polymer injection-molding is one of the most used manufacturing processes for the production of plastic products. Its electricity consumption highly influences its cost as well as its environmental impact. Reducing these factors is one of the challenges that material science and production engineering face today. However, there is currently a lack of data regarding electricity consumption values for injection-molding, which leads to significant errors due to the inherent high variability of injection-molding and its configurations. In this paper, an empirical model is proposed to better estimate the electricity consumption and the environmental impact of the injection-molding process. This empirical model was created after measuring the electricity consumption of a wide range of parts. It provides a method to estimate both electricity consumption and environmental impact, taking into account characteristics of both the molded parts and the molding machine. A case study of an induction cooktop housing is presented, showing adequate accuracy of the empirical model and the importance of proper machine selection to reduce cost, electricity consumption, and environmental impact.