SUSTAINABLE AEROSPACE MANUFACTURING: A COMPARATIVE LIFE CYCLE ASSESSMENT OF NEXT GENERATION AND CONVENTIONAL ALUMINIUM ALLOYS

This study evaluates the environmental and cost sustainability of emerging aluminium alloys and hybrid manufacturing technologies for aerospace applications. Three alloys (AA 7075, AA 2195, and Al-Mg-Sc) and two manufacturing routes (subtractive and hybrid) were compared across two representative case studies: a wing rib and a wing skin. Results demonstrate that hybrid manufacturing (WAAM combined with machining) significantly improves material efficiency and reduces energy consumption and emissions, particularly for complex components. While Al-Mg-Sc offers weight savings that reduce lifecycle emissions during the use phase, the traditional AA 7075 remains the most balanced choice for simpler geometries such as wing skins. Crucially, when all life cycle stages are considered, the use phase consistently dominates overall impacts. This highlights the importance of lightweight design and advanced manufacturing in reducing aviation’s environmental footprint.