Sustainable Manufacturing
Summary
This part of research focuses on sustainable manufacturing, including energy-efficient process planning and scheduling, additive manufacturing and recycling pathways, disassembly and remanufacturing systems for end-of-life products, and the development of sustainable metalworking fluids.
Project
Quantifying Carbon Footprint in Industrial Heat Treatment Processes through Life Cycle Assessment
Funded by: Purdue Heat Treatment Consortium (PHTC)
Introduction: This research targets decarbonization of industrial heat treatment, focusing on gas carburizing—a critical but energy-intensive process for hardening steel parts. A detailed Life Cycle Assessment framework quantifies Scope 1, 2, and 3 emissions, including natural gas use for heating and furnace atmosphere control. By modeling heat transfer and fuel consumption, the work identifies emissions hotspots and opportunities for energy efficiency and cleaner heating alternatives. Scope 1 emissions include flue gases from burning natural gas and endothermic gas production. Scope 2 and 3 indirect emissions are also quantified based on electricity use and upstream supply chain contributions. The goal is to guide industry toward significant emissions reductions and paving the way for more sustainable manufacturing.
Website: PHTC - Materials Engineering - Purdue University
Researchers involved: Lakshmi Srinivasan , Fu Zhao
Publications
Current state and emerging trends in advanced manufacturing: process technologies
K Raoufi, JW Sutherland, F Zhao, AF Clarens, JL Rickli, Z Fan, H Huang, ...
The International Journal of Advanced Manufacturing Technology 1-30, 2024
Current State and Emerging Trends in Advanced Manufacturing: Smart Systems
K Raoufi, K Haapala, J Sutherland, F Zhao, A Clarens, J Rickli, Z Fan, ...
Kamyar Raoufi, Karl Haapala, John Sutherland, Fu Zhao, Andres Clarens … 2024
Driving additive manufacturing towards circular economy: State-of-the-art and future research directions
J Zhao, Y Yang, MH Kobir, J Faludi, F Zhao
Journal of Manufacturing Processes 124, 621-637, 2024
Disassembly time estimation for used smartphones based on Maynard operation sequence technology
X Chu, L Li, F Zhao, JW Sutherland, F Yin
Computers & Industrial Engineering 110291, 2024
Chemical characterization of particulates and volatile organic compounds emitted during fused deposition modeling
TR Simon, F Zhao
Manufacturing Letters 35, 1284-1292, 2023
Comparative Life Cycle Assessment of Injection Molded and Big Area Additive Manufactured NdFeB Bonded Permanent Magnets
S Kulkarni, F Zhao, IC Nlebedim, R Fredette, MP Paranthaman
Journal of Manufacturing Science and Engineering 145 (5), 051001, 2023
Perspectives on future research directions in green manufacturing for discrete products
MJ Triebe, S Deng, JR Perez-Cardona, BG Joung, H Wu, N Shakelly, ...
Green Manufacturing Open 1 (IS-J 11,041), 2023
Disassembly sequence planning for target parts of end-of-life smartphones using Q-learning algorithm
Z Chen, L Li, F Zhao, JW Sutherland, F Yin
Procedia CIRP 116, 684-689, 2023
Integrating line balancing with network topology to support the planning of a remanufacturing system for electric vehicles
S Deng, T Maani, Y Yao, Y Yih, F Zhao, JW Sutherland
Procedia CIRP 116, 215-220, 2023
Exergy-based tool path evaluation method of material and energy flows to support the sustainable-oriented intelligent manufacturing
L Li, C Guo, J Yan, F Zhao, JW Sutherland
Proceedings of the Institution of Mechanical Engineers, Part C: Journal of … 2022
Modelling the effect of slide table mass on machine tool energy consumption: The role of lightweighting
MJ Triebe, F Zhao, JW Sutherland
Journal of Manufacturing Systems 62, 668-680, 2022
Development of a Cost Model for Vertical Milling Machines to Assess Impact of Lightweighting
MJ Triebe, F Zhao, JW Sutherland
Journal of Manufacturing and Materials Processing 5 (4), 129, 2021
Closing the material loop in additive manufacturing: A literature review on waste recycling
Y Yang, F Zhao
IOP Conference Series: Materials Science and Engineering 1196 (1), 2021
Understanding energy consumption of hydraulic press during drawing process
L Li, H Huang, F Zhao, X Zou, Y Ren, Z Liu, JW Sutherland
The International Journal of Advanced Manufacturing Technology 115, 1497-1516, 2020
Industrial sustainability: reviewing the past and envisioning the future
JW Sutherland, SJ Skerlos, KR Haapala, D Cooper, F Zhao, A Huang
Journal of Manufacturing Science and Engineering 142 (11), 110806, 2020
Special Issue on “Energy, Economy and Environment for Industrial Production Processes”
W Cai, G Tian, MC Zhou, F Zhao, J Cunha
Processes 8 (9), 1126, 2020
A multiobjective disassembly planning for value recovery and energy conservation from end-of-life products
Y Ren, H Jin, F Zhao, T Qu, L Meng, C Zhang, B Zhang, G Wang, ...
IEEE Transactions on Automation Science and Engineering 18 (2), 791-803, 2020
An efficient metaheuristics for a sequence-dependent disassembly planning
Y Ren, L Meng, C Zhang, F Zhao, U Saif, A Huang, GP Mendis, ...
Journal of Cleaner Production 245, 118644, 2020
Reusable unit process life cycle inventory for manufacturing: stereolithography
T Simon, Y Yang, WJ Lee, J Zhao, L Li, F Zhao
Production Engineering 13, 675-684, 2019
Variations of energy demand with process parameters in cylindrical drawing of stainless steel
L Li, H Huang, F Zhao, X Zou, Q Lu, Y Wang, Z Liu, JW Sutherland
Journal of Manufacturing Science and Engineering 141 (9), 2019
Topology optimization of oilstone components considering carbon emissions associated with honing processes
Q Lu, G Zhou, F Zhao, Y Ren, L Li, X Luan, JW Sutherland
Journal of Cleaner Production 225, 181-195, 2019
A three-stage method with efficient calculation for lot streaming flow-shop scheduling
H Wang, F Zhao, H Gao, JW Sutherland
Frontiers of Information Technology & Electronic Engineering 20 (7), 1002-1020, 2019
Characterizing the effect of process variables on energy consumption in end milling
L Zhou, F Li, F Zhao, J Li, JW Sutherland
The International Journal of Advanced Manufacturing Technology 101 (9-12), 2019
Reusable unit process life cycle inventory for manufacturing: gas metal arc welding
H Zhang, F Zhao
Production Engineering 13, 89-97, 2019
Modeling and analysis of the process energy for cylindrical drawing
L Li, H Huang, F Zhao, X Zou, GP Mendis, X Luan, Z Liu, JW Sutherland
Journal of Manufacturing Science and Engineering 141 (2), 021001, 2019
Determination of shape and distribution of abrasive grains to reduce carbon emissions of honing process
Q Lu, GH Zhou, F Zhao, L Li, YP Ren
Journal of Manufacturing Science and Engineering 141 (2), 021008, 2019
Achieving Energy Efficient Machine Tools by Mass Reduction through Multi-Objective Optimization
MJ Triebe, F Zhao, JW Sutherland
Procedia CIRP 80, 73-78, 2019
Power measurement in energy efficient manufacturing: Accuracy analysis, Challenges, and Perspectives for improvement
L Li, H Huang, F Zhao, M Gao, Z Liu, JW Sutherland
Procedia CIRP 80, 138-143, 2019
Optimal Joint Production and Emissions Reduction Strategies Considering Consumers’ Environmental Preferences: A Manufacturer’s Perspective
W Tong, J Du, F Zhao, D Mu, JW Sutherland
Sustainability 11 (2), 474, 2019
Understanding Energy Consumption in a Machine Tool through Energy Mapping
MJ Triebe, GP Mendis, F Zhao, JW Sutherland
Procedia CIRP 69, 259-264, 2018
An asynchronous parallel disassembly planning based on genetic algorithm
Y Ren, C Zhang, F Zhao, H Xiao, G Tian
European Journal of Operational Research 269 (2), 647-660, 2018
An MCDM-Based Multiobjective General Variable Neighborhood Search Approach for Disassembly Line Balancing Problem
Y Ren, C Zhang, F Zhao, MJ Triebe, L Meng
IEEE Transactions on Systems, Man, and Cybernetics: Systems 2018
Energy Efficient Manufacturing Process Planning
R Yin, F Zhao, F Zhao, JW Sutherland
Energy Efficient Manufacturing: Theory and Applications 339-358, 2018
Scheduling for Energy Efficient Manufacturing
NA Uhan, AL Liu, F Zhao
Energy Efficient Manufacturing: Theory and Applications 2018
Disassembly line balancing problem using interdependent weights-based multi-criteria decision making and 2-Optimal algorithm
Y Ren, C Zhang, F Zhao, G Tian, W Lin, L Meng, H Li
Journal of Cleaner Production 174, 1475-1486, 2018
Multi-objective optimization of tool path considering efficiency, energy-saving and carbon-emission for free-form surface milling
L Li, X Deng, J Zhao, F Zhao, JW Sutherland
Journal of Cleaner Production 172, 3311-3322, 2018
An Experimental Study on the Energy Consumption and Emission Profile of Fused Deposition Modeling Process
TR Simon, WJ Lee, BE Spurgeon, BE Boor, F Zhao
Procedia Manufacturing 26, 920-928, 2018
Trade-off analysis of tool wear, machining quality and energy efficiency of alloy cast iron milling process
X Luan, S Zhang, J Li, G Mendis, F Zhao, JW Sutherland
Procedia Manufacturing 26, 383-393, 2018
Research needs and recommendations on environmental implications of additive manufacturing
D Rejeski, F Zhao, Y Huang
Additive Manufacturing 19, 21-28, 2018
Product Redesign for Improved Value Recovery via Disassembly Bottleneck Identification and Removal
L Cong, F Zhao, JW Sutherland
Procedia CIRP 61, 81-86, 2017
An energy-saving method by balancing the load of operations for hydraulic press
L Li, H Huang, F Zhao, JW Sutherland, Z Liu
IEEE/ASME Transactions on Mechatronics 22 (6), 2673-2683, 2017
Analysis of a novel energy-efficient system with double-actuator for hydraulic press
L Li, H Huang, F Zhao, MJ Triebe, Z Liu
Mechatronics 47, 77-87, 2017
Operation scheduling of multi-hydraulic press system for energy consumption reduction
L Li, H Huang, F Zhao, Z Liu
Journal of Cleaner Production 165, 1407-1419, 2017
Dynamic Scheduling of a Semiconductor Production Line Based on a Composite Rule Set
Y Ma, F Qiao, F Zhao, JW Sutherland
Applied Sciences 7 (10), 1052, 2017
Selective cooperative disassembly planning based on multi-objective discrete artificial bee colony algorithm
Y Ren, G Tian, F Zhao, D Yu, C Zhang
Engineering Applications of Artificial Intelligence 64, 415-431, 2017
Value recovery from end-of-use products facilitated by automated dismantling planning
L Cong, F Zhao, JW Sutherland
Clean Technologies and Environmental Policy 19, 1867-1882, 2017
Characterization of particle emission from fuse deposition modeling printers
TR Simon, GA Aguilera, F Zhao
ASME 2017 12th International Manufacturing Science and Engineering …, 2017
Dynamic Manufacturing Scheduling Under Real-Time Electricity Pricing Based on MILP and ARIMA
Y Zhai, H Wang, F Zhao, JW Sutherland
International Manufacturing Science and Engineering Conference 50756 …, 2017
Integration of dismantling operations into a value recovery plan for circular economy
L Cong, F Zhao, JW Sutherland
Journal of Cleaner Production 149, 378-386, 2017
Scheduling of a single flow shop for minimal energy cost under real-time electricity pricing
H Zhang, F Zhao, JW Sutherland
Journal of Manufacturing Science and Engineering 139 (1), 014502, 2017
A comparative life cycle assessment (LCA) of lighting technologies for greenhouse crop production
H Zhang, J Burr, F Zhao
Journal of Cleaner Production 140, 705-713, 2017
An energy-saving method to solve the mismatch between installed and demanded power in hydraulic press
L Li, H Huang, Z Liu, X Li, MJ Triebe, F Zhao
Journal of Cleaner Production 139, 636-645, 2016
A multi-level optimization approach for energy-efficient flexible flow shop scheduling
J Yan, L Li, F Zhao, F Zhang, Q Zhao
Journal of Cleaner Production 137, 1543-1552, 2016
A coordinate method applied to partitioned energy-saving control for grouped hydraulic presses
L Li, H Huang, F Zhao, Z Liu
Journal of Manufacturing Systems 41, 102-110, 2016
A Method to Optimize Value Recovery From End-of-Life Products
L Cong, F Zhao, JW Sutherland
ASME 2016 11th International Manufacturing Science and Engineering …, 2016
Scheduling on a single machine under time-of-use electricity tariffs
K Fang, NA Uhan, F Zhao, JW Sutherland
Annals of Operations Research 238 (1), 199-227, 2016
Manufacturing Scheduling of Collaborative Factories for Energy Cost Reduction
H Zhang, F Zhao, JW Sutherland
Procedia Manufacturing 1, 122-133, 2015
Econological scheduling of a manufacturing enterprise operating under a time-of-use electricity tariff
A Sharma, F Zhao, JW Sutherland
Journal of Cleaner Production 108, 256-270, 2015
Environmentally Friendly Machining 29
F Zhao, A Sharma
Energy-efficient scheduling of multiple manufacturing factories under real-time electricity pricing
H Zhang, F Zhao, JW Sutherland
CIRP Annals 64 (1), 41-44, 2015
Remanufacturing of turbine blades by laser direct deposition with its energy and environmental impact analysis
JM Wilson, C Piya, YC Shin, F Zhao, K Ramani
Journal of Cleaner Production 80, 170-178, 2014
Prioritizing design for environment strategies using a stochastic analytic hierarchy process
D Ramanujan, WZ Bernstein, JK Choi, M Koho, F Zhao, K Ramani
Journal of Mechanical Design 136 (7), 071002, 2014
Energy-conscious flow shop scheduling under time-of-use electricity tariffs
H Zhang, F Zhao, K Fang, JW Sutherland
CIRP Annals 63 (1), 37-40, 2014
Sustainable Systems and Technologies, v2 (2014)
F Zhao, A Lagro, G Mendis, C Handwerker,
Environmentally Friendly Machining
F Zhao, A Sharma
Springer 2014
A review of engineering research in sustainable manufacturing
KR Haapala, F Zhao, J Camelio, JW Sutherland, SJ Skerlos, DA Dornfeld, ...
Journal of Manufacturing Science and Engineering 135 (4), 041013, 2013
Flow shop scheduling with peak power consumption constraints
K Fang, NA Uhan, F Zhao, JW Sutherland
Annals of Operations Research 206, 115-145, 2013
Unit Process Life Cycle Inventory Models of Hot Forming Processes
JJ Buis, JW Sutherland, F Zhao
ASME 2013 International Manufacturing Science and Engineering Conference …, 2013
Life cycle analysis of grinding: a case study of non-cylindrical computer numerical control grinding via a unit-process life cycle inventory approach
VR Murray, F Zhao, JW Sutherland
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of … 2012
Toward the development of process plans with reduced environmental impacts
F Zhao, VR Murray, K Ramani, JW Sutherland
Frontiers of Mechanical Engineering 7, 231-246, 2012
Quantifying the water inventory of machining processes
F Zhao, J Ogaldez, JW Sutherland
CIRP Annals 61 (1), 67-70, 2012
Water footprint quantification of machining processes
J Ogaldez, A Barker, F Zhao, JW Sutherland
Leveraging Technology for a Sustainable World: Proceedings of the 19th CIRP …, 2012
A new approach to scheduling in manufacturing for power consumption and carbon footprint reduction
K Fang, N Uhan, F Zhao, JW Sutherland
Journal of Manufacturing Systems 30 (4), 234-240, 2011
Laser-based remanufacturing of engineering components and its environmental impact analysis
JM Wilson, C Piya, V Murray, Y Shin, F Zhao, K Ramani
International Congress on Applications of Lasers & Electro-Optics 2011 (1 …, 2011
Flow shop scheduling for sustainable manufacturing
K Fang, NA Uhan, F Zhao, JW Sutherland
Maxim Sviridenko, IBM Watson Research Center Steef van de Velde, Erasmus … 2011
A review of engineering research in sustainable manufacturing
KR Haapala, F Zhao, J Camelio, JW Sutherland, SJ Skerlos, DA Dornfeld, ...
ASME 2011 International Manufacturing Science and Engineering Conference …, 2011
A new shop scheduling approach in support of sustainable manufacturing
K Fang, N Uhan, F Zhao, JW Sutherland
Glocalized Solutions for Sustainability in Manufacturing: Proceedings of the … 2011
Environmental assessment of laser assisted manufacturing: case studies on laser shock peening and laser assisted turning
F Zhao, WZ Bernstein, G Naik, GJ Cheng
Journal of Cleaner Production 18 (13), 1311-1319, 2010
Environmental Sustainability of Laser-Based Manufacturing: Case Studies on Laser Shock Peening and Laser Assisted Turning
F Zhao, G Naik, L Zhang
ASME 2009 International Manufacturing Science and Engineering Conference, 2010
Evaluation of cooling potential and tool life in turning using metalworking fluids delivered in supercritical carbon dioxide
AF Clarens, YE Park, J Temme, K Hayes, F Zhao, S Skerlos
ASME 2009 International Manufacturing Science and Engineering Conference, 2010
Development of Sustainable Metalworking Fluid Systems
F Zhao
Current advances in sustainable metalworking fluids research
SJ Skerlos, KF Hayes, AF Clarens, F Zhao
International Journal of Sustainable Manufacturing 1 (1-2), 180-202, 2008
Optimization of metalworking fluid microemulsion surfactant concentrations for microfiltration recycling
F Zhao, A Clarens, SJ Skerlos
Environmental Science & Technology 41 (3), 1016-1023, 2007
Structural aspects of surfactant selection for the design of vegetable oil semi-synthetic metalworking fluids
F Zhao, A Clarens, A Murphree, K Hayes, SJ Skerlos
Environmental Science & Technology 40 (24), 7930-7937, 2006
Design of Microfiltration Compatible Metalworking Fluids for Recycling
F Zhao, AF Clarens, SJ Skerlos
Industrial Ecology for a Sustainable Future 2005
Microfiltration recycling of semi-synthetic metalworking fluids: modeling and formulation design
F Zhao
University of Michigan. 2005
Modeling of porous filter permeability via image-based Stochastic reconstruction of spatial porosity correlations
F Zhao, HR Landis, SJ Skerlos
Environmental Science & Technology 39 (1), 239-247, 2005
Mechanistic Model of Coaxial Microfiltration for Semi-Synthetic Metalworking Fluid Microemulsions
F Zhao, M Urbance, SJ Skerlos
Journal of Manufacturing Science and Engineering 126 (3), 435-444, 2004
Ecological Material and Green Manufacturing: Design and Technology for Metalworking Fluid Systems
SJ Skerlos, P Adriaens, K Hayes, J Zimmerman, F Zhao
Proceedings of the World Engineering Congress 2004
Expeditious identification and quantification of mycobacteria species in metalworking fluids using peptide nucleic acid probes
SJ Skerlos, LA Skerlos, CA Aguilar, F Zhao
Journal of Manufacturing Systems 22 (2), 136-147, 2003
Economic and environmental characteristics of global cellular telephone remanufacturing
SJ Skerlos, WR Morrow, K Chan, F Zhao, A Hula, G Seliger, B Basdere, ...
IEEE International Symposium on Electronics and the Environment 2003
Economic considerations in the implementation of microfiltration for metalworking fluid biological control
SJ Skerlos, F Zhao
Journal of Manufacturing Systems 22 (3), 202-219, 2003
Challenges to achieving sustainable aqueous systems: a case study in metalworking fluids
SJ Skerlos, P Adriaens, K Hayes, A Rihana, K Kurabayashi, S Takayama, ...
Proceedings Second International Symposium on Environmentally Conscious … 2001
