Fatigue life prediction of additively manufactured AlSi10Mg based on surface roughness and residual stress

Laser-based powder bed fusion (PBF-LB) has gained prominence in the realm of additive manufacturing of metals. This technique utilizes a laser beam to consolidate powder layers, which inherently introduces high thermal gradients and rapid cooling rates. This results in characteristic process effects, including inhomogeneities, surface roughness, anisotropy, and residual stress, which play a pivotal role in altering the fatigue properties of the manufactured components. This paper presents fatigue tests involving samples of AlSi10Mg manufactured using PBF-LB with varying surface roughness and residual stress. An approach to predict fatigue life based on stress amplitude, residual stress, and crack size is presented, using a smooth sample as a reference. An empirical model for fatigue life prediction is developed from experimentally measured values of fatigue life, peak surface roughness, and residual stress.