Novel electric pulse-based manufacturing process for thin titanium sheets: impact on the environment

This work investigates the sustainability of electro-assisted sheet metal forming using electric pulses, a technology approaching a manufacturing readiness level of 7, in comparison with conventional heat-assisted processing. A comparative Life Cycle Assessment is presented to evaluate the environmental performance of a novel electro-pulsed treatment (EPT) as a replacement for traditional heat treatment (HT) applied prior to Incremental Sheet Forming (ISF) and Deep Drawing (DD) of Ti6Al4V alloy. Four different scenarios were modeled, and Life Cycle Inventory (LCI) data were obtained from both literature sources and a dedicated experimental campaign to ensure high accuracy. The results demonstrate that EPT provides significant environmental advantages, reducing Global Warming Potential by 8–10% compared to HT. Moreover, Cumulative Energy Demand is drastically reduced, by 94.45% for ISF and 93.9% for DD. Overall, the adoption of EPT represents a more sustainable alternative, significantly lowering energy consumption and environmental impacts while improving the formability of Ti6Al4V alloy.