PSI - Issue 77

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ScienceDirect

Procedia Structural Integrity 77 (2026) 681–687

© 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Abstract This study analyses the impact of low-temperature stress-relieving heat treatment on the fatigue life of AlSi10Mg cranks produced by Laser Powder Bed Fusion (L-PBF). The research focuses on a bicycle crankset, comparing its performance in as-built and heat treated conditions. A geometry optimization study was performed, using the Finite Element Method (FEM) to obtain a final model of the pedal with reduced mass and enough fatigue safety. The study found that the as-built condition exhibited a supersaturated Si cellular-dendritic microstructure, while the heat- treated condition showed coarsening of β -Mg2Si phases and Si precipitates. This morphological change led to a decrease in hardness and an increase in ductility. Experimental tests allow to conclude that the reference cranksets and pieces processed by L-PBF with post processing heat treatment could withstand the fatigue life imposed by NP EN ISO 4210-8:2019 standard without failing, but the pieces processed by L-PBF without post processing heat treatment fail below the safety life proposed in the aforementioned standard. International Conference on Structural Integrity Fatigue analysis of AlSi10Mg aluminium alloy cranksets produced by additive manufacturing L.P. Borrego a,b *, J. S. Jesus b , M. J. P. António b , R. Fernandes b , R. Branco b , J.A.M Ferreira b a Polytechnic University of Coimbra, Coimbra Institute of Engineering, Rua Pedro Nunes - Quinta da Nora, 3030-199 Coimbra, Portugal b Department of Mechanical Engineering, CEMMPRE, ARISE, University of Coimbra, 3030-199 Coimbra, Portugal

Peer-review under responsibility of ICSI organizers Keywords: Fatigue, L-PBF, Cranksets, Aluminum alloy.

1. Introduction Additive manufacturing (AM) has revolutionized the production of complex geometries and lightweight components in industries such as aerospace, automotive, and biomedical engineering. Laser Powder Bed Fusion

* Corresponding author. Tel.: +351 962560101; E-mail address: borrego@isec.pt

2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers 10.1016/j.prostr.2026.01.086