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<p>Welding processes are fundamental to modern manufacturing but are often energy-intensive and environmentally burdensome, creating a critical need for sustainable practices. Despite advancements, an integrated analysis of the environmental, technological, and efficiency aspects of welding sustainability is notably absent in the literature. This study addresses this gap through a thorough scoping review of existing research, using frameworks like Life Cycle Assessment (LCA) to synthesize findings on sustainable welding. The results reveal that electricity consumption and filler materials are the dominant sources of environmental impact, accounting for up to 61% and 80% in certain impact categories, respectively. Solid-state processes like Friction Stir Welding (FSW) demonstrate superior sustainability, using approximately 42% less energy than conventional Gas Metal Arc Welding (GMAW). Furthermore, advanced GMAW variants, such as Cold Metal Transfer (CMT), can reduce fume generation rates to as low as 1&#xa0;mg per gram of electrode consumed, a significant reduction from the 13&#xa0;mg/g rate of Shielded Metal Arc Welding (SMAW). Innovations like tandem-wire GMAW can increase energy efficiency by 24% while cutting process time by over 50%. The study concludes that the adoption of advanced, energy-efficient welding technologies is not only technically feasible but also economically advantageous. Strategic implementation of these practices is crucial for fostering an environmentally responsible and economically prosperous industrial future.</p> Graphical Abstract <p></p>

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The role of sustainability in the welding process: Context, technologies and challenges

  • 期刊论文

  • 发表日期：

    2025年10月27日

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  • André Alves de Resende,
  • Carlos Antonio Ribeiro Duarte

摘要

Welding processes are fundamental to modern manufacturing but are often energy-intensive and environmentally burdensome, creating a critical need for sustainable practices. Despite advancements, an integrated analysis of the environmental, technological, and efficiency aspects of welding sustainability is notably absent in the literature. This study addresses this gap through a thorough scoping review of existing research, using frameworks like Life Cycle Assessment (LCA) to synthesize findings on sustainable welding. The results reveal that electricity consumption and filler materials are the dominant sources of environmental impact, accounting for up to 61% and 80% in certain impact categories, respectively. Solid-state processes like Friction Stir Welding (FSW) demonstrate superior sustainability, using approximately 42% less energy than conventional Gas Metal Arc Welding (GMAW). Furthermore, advanced GMAW variants, such as Cold Metal Transfer (CMT), can reduce fume generation rates to as low as 1 mg per gram of electrode consumed, a significant reduction from the 13 mg/g rate of Shielded Metal Arc Welding (SMAW). Innovations like tandem-wire GMAW can increase energy efficiency by 24% while cutting process time by over 50%. The study concludes that the adoption of advanced, energy-efficient welding technologies is not only technically feasible but also economically advantageous. Strategic implementation of these practices is crucial for fostering an environmentally responsible and economically prosperous industrial future.

Graphical Abstract