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Abstract
This study analyzes and compares the casting fault rectification procedure's resource, energy, and environmental impacts. In addition, a casting defect classification approach is provided to categorize them into three categories: more-component, less-component, and unqualified-component. Regarding energy, resources, and the environment, the analysis is conducted. A casting defect process impact model is constructed to obtain a quantitative study of the influence of various casting defects on production status and sustainability. Based on the model, the effect of repairing defects on resources, energy, and the environment for each of the three casting defects is examined. Moreover, it can be concluded from the case that the total impact of less-component defects is the largest, accounting for 50% of total scrap and 60% of resource consumption; the average repair cost of unqualified-component defects is 1.8 times higher than the average, yet their energy regeneration rate can reach 41%; the average resource and energy deviation rate of more-component defects is approximately 5%, yet their resource regeneration rate is 8% to 12% lower than other forms of defects. In conclusion, the model can effectively quantify the sustainability of the casting defect repair process and aid the foundry industry in achieving sustainability.
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