PSI - Issue 77

ScienceDirect Structural Integrity Procedia 00 (2025) 000 – 000 Structural Integrity Procedia 00 (2025) 000 – 000 Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

Procedia Structural Integrity 77 (2026) 119–126

© 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 Abstract This study investigates the fatigue behavior of additively manufactured AlSi10Mg under cyclic loading using Laser Powder Bed Fusion (L-PBF) technology. The research addresses two key aspects: the size effect across three distinct geometries, and the influence of mean stress on one geometry under both push-pull and tension-tension loading conditions. The findings provide valuable insights into how geometry and mean stress affect the fatigue resistance of L-PBF AlSi10Mg, contributing to the optimization of additive manufacturing processes for high-performance applications. © 2025 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 ICSI25 organizers Keywords: High Cycle Fatigue; Additive Manufacturing; Fatigue strength; Mean stress effect; Size effect 1. Introduction Alloy AlSi10Mg is a material that was originally used as a casting material [1] and is characterized by good mechanical properties, good weldability [1], good corrosion resistance and low density [2]. This is why the material is also interesting for use in additive manufacturing. There are studies that provide observations that SLM produced AlSi10Mg have the same or better mechanical properties (e.g., elongation [3]) as cast AlSi10Mg parts [4]. This finding is explained to be caused by the fine microstructure [4], [5] and by the distribution of the Si phase forming the silicon network [4]. Another study came to the conclusion that the AM parts even have a bit higher corrosion resistance than the cast specimens due to a more homogeneous microstructure [6]. International Conference on Structural Integrity Fatigue Behavior of Additively Manufactured AlSi10Mg: Influence of Size Effect and Mean Stress Bastian Roidl 1 , Martin Matušů 1,2 , Jan Papuga 2 , Jakub Rosenthal 1 , Lorenzo Pagliari 3 , Franco Concli 3 , Vladimír Mára 2 , Jan Šimota 2 and Libor Beránek 2 1 Department of Mechanical and Environmental Engineering, OTH Amberg-Weiden, Kaiser-Wilhelm-Ring 23, Amberg 92224, Germany 2 Faculty of Mechanical Engineering, Czech Technical University in Prague. Technická 4, Praha 6, Czech Republic, 3 Faculty of Engineering, Free University of Bozen-Bolzano - via Bruno Buozzi, 1 39100 Bolzano * corresponding author: b.roidl@oth-aw.de Abstract This study investigates the fatigue behavior of additively manufactured AlSi10Mg under cyclic loading using Laser Powder Bed Fusion (L-PBF) technology. The research addresses two key aspects: the size effect across three distinct geometries, and the influence of mean stress on one geometry under both push-pull and tension-tension loading conditions. The findings provide valuable insights into how geometry and mean stress affect the fatigue resistance of L-PBF AlSi10Mg, contributing to the optimization of additive manufacturing processes for high-performance applications. © 2025 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 ICSI25 organizers Keywords: High Cycle Fatigue; Additive Manufacturing; Fatigue strength; Mean stress effect; Size effect 1. Introduction Alloy AlSi10Mg is a material that was originally used as a casting material [1] and is characterized by good mechanical properties, good weldability [1], good corrosion resistance and low density [2]. This is why the material is also interesting for use in additive manufacturing. There are studies that provide observations that SLM produced AlSi10Mg have the same or better mechanical properties (e.g., elongation [3]) as cast AlSi10Mg parts [4]. This finding is explained to be caused by the fine microstructure [4], [5] and by the distribution of the Si phase forming the silicon network [4]. Another study came to the conclusion that the AM parts even have a bit higher corrosion resistance than the cast specimens due to a more homogeneous microstructure [6]. International Conference on Structural Integrity Fatigue Behavior of Additively Manufactured AlSi10Mg: Influence of Size Effect and Mean Stress Bastian Roidl 1 , Martin Matušů 1,2 , Jan Papuga 2 , Jakub Rosenthal 1 , Lorenzo Pagliari 3 , Franco Concli 3 , Vladimír Mára 2 , Jan Šimota 2 and Libor Beránek 2 1 Department of Mechanical and Environmental Engineering, OTH Amberg-Weiden, Kaiser-Wilhelm-Ring 23, Amberg 92224, Germany 2 Faculty of Mechanical Engineering, Czech Technical University in Prague. Technická 4, Praha 6, Czech Republic, 3 Faculty of Engineering, Free University of Bozen-Bolzano - via Bruno Buozzi, 1 39100 Bolzano * corresponding author: b.roidl@oth-aw.de

2452-3216 © 2025 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 ICSI25 organizers 2452-3216 © 2025 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 ICSI25 organizers

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.2026.01.017