Research and analysis of automotive half shaft remanufacturing assessment and carbon footprint accounting

Abstract Automotive half‐shaft remanufacturing serves as a pivotal strategy for sustainable manufacturing, though comprehensive assessments of its structural reliability and ecological advantages are still lacking. This research tackles two critical gaps: (1) devising a non‐destructive defect identification technique utilizing modal analysis, and (2) conducting a comparative carbon footprint analysis between remanufactured and newly produced components. Experimental findings reveal that natural frequency reduction correlates strongly with crack depth and positioning, with higher‐order modes demonstrating superior damage sensitivity—a breakthrough for flaw categorization. Moreover, the developed lifecycle carbon model pinpoints material production (contributing 50% of total emissions) and heat treatment as the most emission‐intensive stages in conventional manufacturing. Remanufacturing achieves 30–40% emission reductions, predominantly via material recycling. The innovative quantification framework, incorporating material flows, energy consumption, and waste emissions, establishes the first empirically verified model specific to half‐shaft remanufacturing. This study not only refines structural diagnostics but also delivers actionable data to guide automotive circular economy policies.