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The fatigue performance of AlSi10Mg alloy produced via Laser Powder Bed Fusion (L-PBF) is crucial for its application in structural components, particularly in hybrid metal-composite interlocking joints. This study investigates the influence of sample topology, load type, and process parameters on the fatigue behavior of L-PBF AlSi10Mg specimens. Notched geometries are analyzed to evaluate local stress intensification effects, while different cyclic loading conditions are considered. Additionally, the impact of key process-related factors—such as build orientation and post-processing heat treatments—is assessed. Special attention is given to the interaction between standard heat treatment procedures and the thermal exposure during composite curing in autoclave, which alters the alloy’s microstructural evolution and mechanical properties. The experimental characterization provides insights into the fatigue reliability of L-PBF AlSi10Mg under realistic service conditions, supporting the improvement of process setups and design strategies for enhanced durability in advanced engineering applications.

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Fatigue Characterization of L-PBF AlSi10Mg Alloy for Fastener-Free Aeronautic Joints

  • 会议论文

  • 发表日期：

    2026年

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  • Giorgio De Pasquale,
  • Luca Margaria,
  • Antonio Coluccia

摘要

The fatigue performance of AlSi10Mg alloy produced via Laser Powder Bed Fusion (L-PBF) is crucial for its application in structural components, particularly in hybrid metal-composite interlocking joints. This study investigates the influence of sample topology, load type, and process parameters on the fatigue behavior of L-PBF AlSi10Mg specimens. Notched geometries are analyzed to evaluate local stress intensification effects, while different cyclic loading conditions are considered. Additionally, the impact of key process-related factors—such as build orientation and post-processing heat treatments—is assessed. Special attention is given to the interaction between standard heat treatment procedures and the thermal exposure during composite curing in autoclave, which alters the alloy’s microstructural evolution and mechanical properties. The experimental characterization provides insights into the fatigue reliability of L-PBF AlSi10Mg under realistic service conditions, supporting the improvement of process setups and design strategies for enhanced durability in advanced engineering applications.