Notch Sensitivity of AlSi10Mg Aluminum Alloy Produced by Laser Powder Bed Fusion Process

Stress gradient influence factors and fatigue notch factors were measured for the AlSi10Mg aluminum alloy produced by laser powder bed fusion (L-PBF) processing with respect to different stress gradients (notch geometries). Modeling the stress gradient is critical for accurate fatigue life estimations for parts containing notches or fillets. Uniaxial fatigue tests were performed to obtain the fatigue strengths at R = −1 for notched and unotched specimens. The fatigue results were then used to calibrate the stress gradient influence factor model for fatigue life estimation. Due to the small grain size produced by the L-PBF process, the stress gradient influence factor is much lower compared to the cast A319-T7 alloy (at 120 °C) at the same stress gradient.