Abstract
The fatigue life of a high-pressure die-cast alloy, AlSi9Cu3, with significant porosity is investigated. Standard specimens were cyclically loaded (R = –1) until fatigue rupture occurred. The specimens were μ-CT scanned to obtain a 3D representation of the pores. Models were used to computationally predict the fatigue life using two different methods. First, the fatigue life was predicted using a notch-strain approach combined with a Coffin-Manson durability relationship for homogeneous material. Second, the fatigue life was predicted using an homogenised un-notched model that was combined with an adapted Coffin-Manson relationship which considered a fatigue life reduction due to different pore effects.
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