Abstract
Residual defects in additively manufactured metal parts are known to degrade fatigue performance. In this work, pores and oxide particles in AlSi10Mg parts produced by selective laser melting were characterized and quantified by automated scanning electron microscopy (SEM). The fracture surfaces were examined after fatigue tests to identify the critical role of defects in fatigue failure. A correlation between the crack-initiating pore on the fracture surface and fatigue life was established. The pore size distribution measured on a 2D section by scanning electron microscope was used to predict fatigue life using extreme-value theory; good agreement was achieved.
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