Sustainability Assessment of Machining Processes in Turbine Disk Production: From Data Acquisition to Digital Anchoring in the PCF AAS Submodel

Over the past decades, global air traffic has increased continuously, with passenger kilometers roughly doubling every fifteen to twenty years, and this trend is estimated to continue, with some adjustments due to COVID-19 impact. In response to the resulting environmental challenges, the European initiatives Flightpath 2050 and Clean Sky serve as central drivers of technological development aimed at achieving ambitious sustainability goals. Flightpath 2050 targets, relative to a reference engine from the year 2000, include a 75% reduction in CO2 emissions per passenger kilometer, a 90% reduction in NOx emissions, and a 65% reduction in noise emissions. These objectives highlight the urgent need for emission reduction strategies across all manufacturing domains, including turbine component production. This study evaluates the environmental impacts of the preturning and roughing operations employed in turbine disk production. The analysis focuses on these specific processes rather than the entire product, as the approach of process-level Life Cycle Assessments (LCA) are more universally applicable across different products, and their systematic combination can ultimately form a comprehensive product-level LCA. Operational data, such as energy usage, cooling lubricants, and compressed air, were gathered and processed from the equipment involved in manufacturing. The collected data were analyzed and modeled in Spheras life cycle assessment software LCA for Experts (version 10.9.0.20) to quantify the environmental effects of each process. The findings of the current research emphasize notable patterns of resource utilization and their respective environmental impacts. Furthermore, the Industrial Digital Twin Association (IDTA) Product Carbon Footprint (PCF) template was utilized to present the findings in a standardized manner, enabling effective data transfer between stakeholders. The results demonstrate the critical need to leverage machine data for sustainability analysis, providing inputs for industry practice enhancement and progress toward better environmental performance.