A novel life cycle assessment and life cycle costing framework for carbon fibre-reinforced composite materials in the aviation industry

PURPOSE: Carbon fibre-reinforced composite materials offer superior mechanical properties and lower weight than conventional metal products. However, relatively, little is known about the environmental impacts and economic costs associated with composite products displacing conventional metal products. The purpose of this study is to develop an integrated life cycle assessment and life cycle costing framework for composite materials in the aviation industry. METHODS: An integrated life cycle assessment (LCA) and life cycle costing (LCC) framework has been developed. The displacement of a conventional aluminium door for an aircraft by a composite door is presented as an example of the use of this framework. A graphical visualisation tool is proposed to model the integrated environmental and economic performances of this displacement. LCA and LCC models for composite applications are developed accordingly. The environmental hotspots are identified, and the sensitivity of the environmental impact results to the different composite waste treatment routes is performed. Subsequently, the research suggests a learning curve to analyse the unit price for competitive mass production. Sensitivity analysis and Monte Carlo simulation have been applied to demonstrate the cost result changes caused by data uncertainty. RESULTS: Energy consumption was the hotspot, and the choice of composite waste treatment routes had a negligible effect on the LCA outcomes. Concerning the costs, the most significant cost contribution for the unit door production was labour. The future door production cost was decreased by about 29% based on the learning curve theory. The uncertainties associated with the variables could lead to variations in the production cost of up to about 16%. The comparison between the two doors shows that the composite door had higher potential environmental impacts and cost compared to the conventional aluminium door during the production stage. However, the composite door would have better environmental and financial performance if a weight reduction of 47% was achieved in future designs. CONCLUSIONS: The proposed framework and relevant analysis models were applied through a case study in the aerospace industry, creating a site-specific database for the community to support material selection and product development. The graphical tool was proved to be useful in representing a graphical visualisation comparison based on the integration of the LCA and LCC results of potential modifications to the composite door against the reference door, providing understandable information to the decision-makers. SUPPLEMENTARY INFORMATION: The online version contains supplementary material available at 10.1007/s11367-023-02164-y.