Joining of hybrid busbars for E-Mobility: An economic and environmental study

This paper presents a model to evaluate and analyze the costs of joining hybrid (copper-aluminum) busbars when different production processes are deployed. The process-based cost model (PBCM) is built upon the subdivision of the production cycle in three different stages related with the fabrication...

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Bibliographic Details
Published in:	Journal of advanced joining processes Vol. 8; p. 100159
Main Authors:	Pragana, João PM, Sapage, Miguel ST, Sampaio, Rui FV, Bragança, Ivo MF, Ribeiro, Ines, Silva, Carlos MA, Martins, Paulo AF
Format:	Journal Article
Language:	English
Published:	Elsevier B.V 01-11-2023 Elsevier
Subjects:	Fastening Hybrid busbars Joining by forming Life cycle assessment Process-based cost modelling Welding Joining by forming Life cycle assessment Hybrid busbars Process-based cost modelling Fastening Welding
Online Access:	Get full text
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Summary:	This paper presents a model to evaluate and analyze the costs of joining hybrid (copper-aluminum) busbars when different production processes are deployed. The process-based cost model (PBCM) is built upon the subdivision of the production cycle in three different stages related with the fabrication or purchase of auxiliary joining elements, preparation of the individual copper and aluminum conductors, and final joining of the hybrid busbars. The total cost per hybrid busbar is obtained by converting the major physical, human, and financial resources associated with the production cycle into itemized costs that make use of the expenses in materials, labor working hours, number and usage time of machines and tools, among other production costs. Application of the PBCM is illustrated with three different joining processes and enriched with a life cycle assessment (LCA) focused on the environmental performance of hybrid busbars throughout its fabrication, service use and end of life. The combined economic and environmental sustainability analysis of joining hybrid busbars allows concluding that despite conventional fastening being the cheaper process it has the highest environmental impact due to the use of bolts, nuts and washers made from galvanized medium carbon steel. Injection lap riveting arises to be the most well-balanced process in terms of production cost and environmental impact.
ISSN:	2666-3309 2666-3309
DOI:	10.1016/j.jajp.2023.100159