Abstract
Plain fatigue, fatigue crack growth and fretting fatigue tests were carried out using cast Al–Si aluminum alloy JIS AC4CH–T6 as well as the forged aluminum alloy JIS 6061–T6. Plain fatigue strength of the cast aluminum alloy was lower than that of the forged alloy. The lower fatigue strength was attributed to casting defects such as pores in the cast aluminum alloy, which enhanced fatigue crack formation. On the other hand, fretting fatigue strength of the cast aluminum alloy was almost equal to that of the forged alloy. No difference of both tangential force coefficient in fretting fatigue and fatigue crack growth rates were observed between the two materials. The prediction of fretting fatigue lives for both materials were made on the basis of the fracture mechanics approach. The predicted lives were in good agreement with the experimental results.
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