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An equivalent stress approach for predicting fatigue behavior of additively manufactured AlSi10Mg
- Laser-based powder bed fusion (PBF-LB) is an advanced additive manufacturing technique renowned for its precision and capability to fabricate complex metal components. However, the high thermal gradients and rapid cooling rates intrinsic to this process introduce significant process-induced effects, such as inhomogeneities, surface roughness, anisotropy, and residual stress, all of which critically influence the fatigue behavior of the produced parts. This study investigates the fatigue performance of AlSi10Mg samples produced by PBF-LB, examining the impact of varying surface conditions, geometries, and residual stress levels. Fatigue-life prediction models are formulated based on nominal stress amplitude, residual stress, form factor, crack-initiating inhomogeneity, and surface roughness, with smooth samples serving as a baseline reference. The study presents two empirical models for predicting fatigue life and fatigue strength using S–N curves and the Kitagawa–Takahashi diagram withLaser-based powder bed fusion (PBF-LB) is an advanced additive manufacturing technique renowned for its precision and capability to fabricate complex metal components. However, the high thermal gradients and rapid cooling rates intrinsic to this process introduce significant process-induced effects, such as inhomogeneities, surface roughness, anisotropy, and residual stress, all of which critically influence the fatigue behavior of the produced parts. This study investigates the fatigue performance of AlSi10Mg samples produced by PBF-LB, examining the impact of varying surface conditions, geometries, and residual stress levels. Fatigue-life prediction models are formulated based on nominal stress amplitude, residual stress, form factor, crack-initiating inhomogeneity, and surface roughness, with smooth samples serving as a baseline reference. The study presents two empirical models for predicting fatigue life and fatigue strength using S–N curves and the Kitagawa–Takahashi diagram with the El Haddad approach, derived from comprehensive experimental data, including finite element modeling, fatigue-life measurements, surface roughness evaluations, and residual stress analysis.…


| Autor*innen: | Lea StraußORCiD, Larissa DuarteORCiD, Julius Kruse, Mauro MadiaORCiD, Günther Löwisch |
|---|---|
| Dokumenttyp: | Zeitschriftenartikel |
| Veröffentlichungsform: | Verlagsliteratur |
| Sprache: | Englisch |
| Titel des übergeordneten Werkes (Englisch): | Progress in Additive Manufacturing |
| Jahr der Erstveröffentlichung: | 2025 |
| Organisationseinheit der BAM: | 9 Komponentensicherheit |
| 9 Komponentensicherheit / 9.4 Integrität von Schweißverbindungen | |
| Veröffentlichende Institution: | Bundesanstalt für Materialforschung und -prüfung (BAM) |
| Verlag: | Springer Science and Business Media LLC |
| Erste Seite: | 1 |
| Letzte Seite: | 16 |
| DDC-Klassifikation: | Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten |
| Freie Schlagwörter: | AlSi10Mg; El Haddad; Equivalent stress; Fatigue-life prediction; Kitagawa–Takahashi diagram; PBF-LB/M |
| Themenfelder/Aktivitätsfelder der BAM: | Material |
| Material / Additive Fertigung | |
| DOI: | 10.1007/s40964-025-00974-0 |
| URN: | urn:nbn:de:kobv:b43-625176 |
| Verfügbarkeit des Dokuments: | Datei für die Öffentlichkeit verfügbar ("Open Access") |
| Lizenz (Deutsch): | Creative Commons - CC BY - Namensnennung 4.0 International |
| Datum der Freischaltung: | 10.02.2025 |
| Referierte Publikation: | Ja |
| Datum der Eintragung als referierte Publikation: | 19.02.2025 |
| Schriftenreihen ohne Nummerierung: | Wissenschaftliche Artikel der BAM |


