Comparative Life Cycle Assessment and Cost Analysis of the Production of Ti6Al4V-TiC Metal-Matrix Composite Powder by High-Energy Ball Milling and Ti6Al4V Powder by Gas Atomization

Environmental awareness and the necessary reduction in costs in industrial processes has facilitated the development of novel techniques such as Additive Manufacturing, decreasing the amount of raw materials and energy needed. The longing for improved materials with different and enhanced properties has resulted in research efforts in the Metal Matrix Composites field. These two novelties combined minimise environmental impacts and costs without compromising technical properties. Two technologies can feed Additive Manufacturing techniques with metallic powder: Gas Atomization and High Energy Ball Milling. This study provides a comparative Life Cycle Assessment of these technologies to produce one kilogram of metallic powder for the Directed Energy Deposition technique: a Ti6Al4V alloy, and a Ti6Al4V-TiC Metal-Matrix Composite, respectively. The LCA methodology is according to ISO 14040:2006, and large amounts of information on the use of raw materials, energy consumption, and environmental impacts is provided. Different impact categories following the Environmental Footprint methodology were analysed, showing a big difference between both technologies, with an 87.8% reduction of kg CO2 eq. emitted by High Energy Ball Milling in comparison with Gas Atomization. In addition, an economic analysis was performed, addressing the viability perspective and decision making and showing a 17.2% cost reduction in the conventional process.