Enhanced Fatigue Resistance Research Articles

Wing–antenna interaction reduces odour fatigue in butterfly odour-tracking flight

Flying insects exhibit remarkable capabilities in coordinating their olfactory sensory system and flapping wings during odour plume-tracking flights. While observations have indicated that their flapping wing motion can ‘sniff’ up the incoming plumes for better odour sampling range, how flapping motion impacts the odour concentration field around the antennae is unknown. Here, we reconstruct the body and wing kinematics of a forwards-flying butterfly based on high-speed images. Using an in-house computational fluid dynamics solver, we simulate the unsteady flow field and odourant transport process by solving the Navier–Stokes and odourant advection-diffusion equations. Our results show that, during flapping flight, the interaction between wing leading-edge vortices and antenna vortices strengthens the circulation of antenna vortices by over two-fold compared with cases without flapping motion, leading to a significant increase in odour intensity fluctuation along the antennae. Specifically, the interaction between the wings and antennae amplifies odour intensity fluctuations on the antennae by up to 8.4 fold. This enhancement is critical in preventing odour fatigue during odour-tracking flights. Further analysis reveals that this interaction is influenced by the inter-antennal angle. Adjusting this angle allows insects to balance between resistance to odour fatigue and the breadth of odour sampling. Narrower inter-antennal angles enhance fatigue resistance, while wider angles extend the sampling range but reduce resistance. Additionally, our findings suggest that while the flexibility of the wings and the thorax's pitching motion in butterflies do influence odour fluctuation, their impact is relatively secondary to that of the wing–antenna interaction.

Advancing laser powder bed fusion with non-spherical powder: Powder-process-structure-property relationships through experimental and analytical studies of fatigue performance

This study investigates the multifaceted interdependencies among powder characteristics (i.e., non-spherical morphology and particle size ranging 50-120 or 75-175µm), laser powder bed fusion (L-PBF) process condition (i.e., contouring), post-process treatments (i.e., hot isostatic pressing (HIP) and mechanical grinding) on the pore, microstructure, surface finish, and fatigue behavior of additively manufactured Ti-6Al-4V samples. Microstructure analysis shows a phase transformation α′ → α+β microstructure after HIP treatment (at 899±14 °C for 2h under the applied pressure of 1034±34bar) of the as-built Ti-6Al-4V parts. The findings from pore analysis using micro-computed tomography (μ-CT) show an increase in sub-surface pores when relatively smaller powders are L-PBF processed including contouring. Surface optical profilometry reveals a decrease in surface roughness when fine powder is L-PBF including contouring. Pore analysis conducted through μ-CT reveals that the presence of lack-of-fusion pores within the L-PBF processed coarse powder is more pronounced when compared to the fine powder. Furthermore, HIP treatment does not eliminate these pores. The fracture failure in as-printed parts occurs at the surface, while the combination of HIP and mechanical grinding alters crack initiation to subsurface pore defects. Fractography reveals that HIP and as-built samples followed the facet formation and pseudo-brittle fracture mechanisms, respectively. Fatigue life assessments, supported by statistical analysis, indicate that mechanical grinding and HIP significantly enhanced fatigue resistance, approaching the benchmarks set by wrought Ti-6Al-4V alloy. A fatigue prediction model which considers the surface roughness as a micro-notch has been used.

Enhancing fatigue resistance of Cr-Mn-Fe-Co-Ni multi-principal element alloys by varying stacking fault energy and sigma (σ)-phase assisted grain-size reduction

Enhancing fatigue resistance of Cr-Mn-Fe-Co-Ni multi-principal element alloys by varying stacking fault energy and sigma (σ)-phase assisted grain-size reduction

Enhanced Fatigue Resistance of Liquid Crystal Elastomers Enabled by Dynamic Sacrificial Bonds

Enhanced Fatigue Resistance of Liquid Crystal Elastomers Enabled by Dynamic Sacrificial Bonds

Enhancing Fatigue Resistance of Polylactic Acid through Natural Reinforcement in Material Extrusion.

This research paper aims to enhance the fatigue resistance of polylactic acid (PLA) in Material Extrusion (ME) by incorporating natural reinforcement, focusing on rotational bending fatigue. The study investigates the fatigue behavior of PLA in ME, using various natural fibers such as cellulose, coffee, and flax as potential reinforcements. It explores the optimization of printing parameters to address challenges like warping and shrinkage, which can affect dimensional accuracy and fatigue performance, particularly under the rotational bending conditions analyzed. Cellulose emerges as the most promising natural fiber reinforcement for PLA in ME, exhibiting superior resistance to warping and shrinkage. It also demonstrates minimal geometrical deviations, enabling the production of components with tighter dimensional tolerances. Additionally, the study highlights the significant influence of natural fiber reinforcement on the dimensional deviations and rotational fatigue behavior of printed components. The fatigue resistance of PLA was significantly improved with natural fiber reinforcements. Specifically, PLA reinforced with cellulose showed an increase in fatigue life, achieving up to 13.7 MPa stress at 70,000 cycles compared to unreinforced PLA. PLA with coffee and flax fibers also demonstrated enhanced performance, with stress values reaching 13.6 MPa and 13.5 MPa, respectively, at similar cycle counts. These results suggest that natural fiber reinforcements can effectively improve the fatigue resistance and dimensional stability of PLA components produced by ME. This paper contributes to the advancement of additive manufacturing by introducing natural fiber reinforcement as a sustainable solution to enhance PLA performance under rotational bending fatigue conditions. It offers insights into the comparative effectiveness of natural fibers and synthetic counterparts, particularly emphasizing the superior performance of cellulose.

Comparative fatigue performance of as-built vs etched Ti64 in TPMS-gyroid and stochastic structures fabricated via PBF-LB for biomedical applications

PurposeThis study compares the fatigue performance and biocompatibility of as-built and chemically etched Ti-6Al-4V alloys in TPMS-gyroid and stochastic structures fabricated via Powder Bed Fusion Laser Beam (PBF-LB). This study aims to understand how complex lattice structures and post-manufacturing treatment, particularly chemical etching, affect the mechanical properties, surface morphology, fatigue resistance and biocompatibility of these metamaterials for biomedical applications.Design/methodology/approachSelective Laser Melting (SLM) technology was used to fabricate TPMS-gyroid and Voronoi stochastic designs with three different relative densities (0.2, 0.3 and 0.4) in Ti-6Al-4V ELI alloy. The as-built samples underwent a chemical etching process to enhance surface quality. Mechanical characterization included static compression and dynamic fatigue testing, complemented by scanning electron microscopy (SEM) for surface and failure analysis. The biocompatibility of the samples was assessed through in-vitro cell viability assays using the Alamar Blue assay and cell proliferation studies.FindingsChemical etching significantly improves the surface morphology, mechanical properties and fatigue resistance of both TPMS-gyroid and stochastic structures. Gyroid structures demonstrated superior mechanical performance and fatigue resistance compared to stochastic structures, with etching providing more pronounced benefits in these aspects. In-vitro biocompatibility tests showed high cytocompatibility for both as-built and etched samples, with etched samples exhibiting notably improved cell viability. The study also highlights the importance of design and post-processing in optimizing the performance of Ti64 components for biomedical applications.Originality/valueThe comparative analysis between as-built and etched conditions, alongside considering different lattice designs, provides valuable information for developing advanced biomedical implants. The demonstration of enhanced fatigue resistance and biocompatibility through etching adds significant value to the field of additive manufacturing, suggesting new avenues for designing and post-processing implantable devices.

Nacre-like surface nanolaminates enhance fatigue resistance of pure titanium

Fatigue failure is invariably the most crucial failure mode for metallic structural components. Most microstructural strategies for enhancing fatigue resistance are effective in suppressing either crack initiation or propagation, but often do not work for both synergistically. Here, we demonstrate that this challenge can be overcome by architecting a gradient structure featuring a surface layer of nacre-like nanolaminates followed by multi-variant twinned structure in pure titanium. The polarized accommodation of highly regulated grain boundaries in the nanolaminated layer to cyclic loading enhances the structural stability against lamellar thickening and microstructure softening, thereby delaying surface roughening and thus crack nucleation. The decohesion of the nanolaminated grains along horizonal high-angle grain boundaries gives rise to an extraordinarily high frequency (≈1.7 × 103 times per mm) of fatigue crack deflection, effectively reducing fatigue crack propagation rate (by 2 orders of magnitude lower than the homogeneous coarse-grained counterpart). These intriguing features of the surface nanolaminates, along with the various toughening mechanisms activated in the subsurface twinned structure, result in a fatigue resistance that significantly exceeds those of the homogeneous and gradient structures with equiaxed grains. Our work on architecting the surface nanolaminates in gradient structure provides a scalable and sustainable strategy for designing more fatigue-resistant alloys.

Design and molecular dynamics of biocompatible WPU/PVA composite hydrogels with enhanced fatigue resistance: Energy dissipation of intermolecular clusters for elastomers

To engineer a hydrogel elastomer for use as an in vivo tissue replacement, it is imperative to ensure superior fatigue resistance, guaranteeing a prolonged service life. Investigating the molecular mechanisms of strain energy accumulation and transmission, which occur during the compression of elastomeric materials, is instrumental in elucidating the causes of hydrogel material fatigue. Such insights are of immense value for the development of durable artificial tissue replacements, ensuring their longevity and sustained functionality within the human body. We synthesized hydrogel elastomers through polyvinyl alcohol (PVA) and waterborne polyurethane (WPU) with good biocompatibility, and studied their fatigue behavior through molecular dynamics (MD). The results of this analysis demonstrate that the introduction of energy dissipation structures between mechanically supported molecular frameworks can enhance the relaxation efficiency of polymers. This improvement leads to enhanced resistance of hydrogels to compression fatigue. A total of 1,000,000 cycles of compression tests were conducted to verify that WPU/PVA did not exhibit any significant compression fatigue under high stress of 50 % strain. In contrast, PVA hydrogel exhibited obvious fatigue due to the absence of an energy dissipation structure. These results revealed the source of compression fatigue resistance of hydrogel elasticity and provided powerful guidance for the design and synthesis of artificial tissues.

Analysing the Impact of Severe Shot Peening on the Fatigue Strength of Wire Arc Additively Manufactured Carbon Steel

The study investigates the impact of severe shot peening on the fatigue strength of wire arc additively manufactured carbon steel. Initial characterization revealed a material with prominent equiaxed grains and large grain sizes. However, the application of SSP induced a considerable reduction in grain size, particularly on the surface, consequently enhancing the surface's strength and hardness, yet leading to an inhomogeneous structure within the WAAM CS SSP part. Hardness measurements demonstrated a substantial impact on surface hardness, reaching a depth of approximately 0.4 mm, with a 64% increase observed due to SSP, elevating it from an average of 165 HV to a maximum of 270 HV near the surface. Tensile tests on WAAM CS and WAAM CS SSP displayed notable improvements in mechanical properties following SSP treatment. Yield strength increased by approximately 5%, and ultimate tensile strength rose by 2.5%, resulting in a peak tensile strength of 513 MPa. However, this enhancement was accompanied by reduced ductility, evidenced by decreased elongation from 44% in WAAM CS to 35% in WAAM CS SSP. Bending fatigue tests highlighted a significant enhancement in fatigue resistance due to SSP treatment. The fatigue limit increased by 21% from 190 MPa for WAAM CS to 230 MPa for WAAM CS SSP, indicating improved resistance in both low-cycle and high-cycle fatigue regimes. This enhancement in fatigue resistance is attributed to the heightened mechanical strength post-SSP treatment, suggesting a trade-off between increased strength and reduced ductility. The results demonstrate that SSP significantly enhances surface attributes, strength, and fatigue resistance of WAAM CS. This advancement bears implications for engineering applications where enhanced mechanical properties and fatigue resistance are vital, despite the induced trade-offs in material characteristics.

Monitoring Crack Tip Position in Adhesively Bonded Joints Under Mixed I+II Mode Loading

The use of adhesive joints has gained favour in recent years, due to their capacity for weight reduction, improved stress distribution, and enhanced fatigue resistance. However, the widespread use of adhesive joints in structural applications is hindered, because reliable and mature inspection and defect detection techniques are not yet available. Adhesive joints in structural applications are subject to fatigue loading, during which debonds can initiate and propagate, ultimately leading to potential failure. In the majority of cases, joints operate under mixed-mode loading conditions. In this work, steel Cracked Lap Shear specimens were tested to investigate the crack growth behaviour of adhesive joints under mixed I+II mode loading. To address the challenge of monitoring these joints, a range of experimental techniques was employed. These techniques included Visual testing, Digital Image Correlation, Optical Backscatter Reflectometry, and localization by Acoustic Emission. The different methods were evaluated and compared to determine their effectiveness in locating the crack tip within the joints during fatigue propagation.

Effect of fiber characteristic parameters on the synergistic action and mechanism of basalt fiber asphalt mortar

Basalt fiber has been shown to significantly improve the performance of asphalt mixtures and extend the lifespan of roads. However, more research is needed to investigate the characteristic parameters of basalt fiber when used in asphalt mortar and asphalt mixture. In order to enhance the reinforcing effect of basalt fiber on asphalt mixture and understand how it works, this study examines the properties of asphalt mortar mixed with basalt fiber with different characteristic parameters. Nine types of basalt fibers with varying characteristic parameters were selected for this work, including three lengths (3 mm, 6 mm, 12 mm) and three diameters (7 μm, 16 μm, 25 μm). The properties of asphalt mortar mixed with basalt fiber with different characteristic parameters were tested. High-temperature properties were characterized using the ZSV and MSCR tests; medium-temperature properties were characterized using the LAS test; low-temperature properties were characterized using the BBR and direct tensile tests. In addition, the effects of fiber characteristics on the viscosity, structural integrity and interfacial properties of asphalt mortar were analyzed through the bond strength test, Rigden porosity test and fiber monofilament drawing test. The results demonstrate that basalt fiber can improve high-temperature properties significantly in asphalt mortar while being greatly influenced by its characteristic parameters. Specifically, fibers with a length of 6 mm and a diameter of 7 μm exhibit superior reinforcement effects. Fatigue life results indicate that basalt fiber enhances fatigue resistance in asphalt mortar as well; furthermore, the influence exerted by fiber characteristic parameters aligns consistently with that observed for high-temperature performance. Although the BBR test results indicate that fiber incorporation has minimal impact on its enhancement, the direct tensile test results demonstrate a significant improvement in the toughness of asphalt mortar due to fiber reinforcement. The addition of basalt fiber enhances the bond strength of asphalt mortar. According to Einstein viscosity formula, the viscosity of asphalt mortar decreases with shorter fiber lengths and larger diameters. Incorporating basalt fiber can enhance the proportion and strength of structural asphalt in asphalt mortar. When comparing fibers with equal diameter or length, an increase in either parameter initially improves the strength of structural asphalt but eventually leads to a decline. Results from monofilament fiber drawing tests and theoretical critical embedding length confirm that a 6 mm fiber length is most beneficial for enhancing the performance of asphalt mortar. Basalt fiber exhibits significant potential for improving various properties of asphalt mortar and provides a favorable reference for optimizing the selection of basalt fiber.

Fatigue properties of SiC graded ceramic lattice structures with a triply periodic minimal surface manufactured by laser powder bed fusion

SiC graded ceramic lattice structure (GCLS) offers superior mechanical strength and its impact on fatigue warrants investigation. In this work, SiC triply periodic minimal surface (TPMS) GCLSs were prepared via laser powder bed fusion technology and liquid silicon infiltration process, alongside SiC TPMS uniform ceramic lattice structure (UCLS) as a reference. Fatigue properties, fatigue failure, and strengthening mechanisms were systematically investigated through compression fatigue tests, finite element (FE) simulations, and theoretical analysis. Fatigue failures of SiC UCLSs and GCLSs are influenced by cyclic ratcheting and fatigue damage, with cyclic ratcheting dominance. The fatigue strength ratios of UCLS and GCLS are 0.7 and 0.74, indicating that GCLSs exhibit stronger deformation resistance and superior fatigue performance. FE results show that surface tensile stress level in GCLS is lower than in UCLS, resulting in slower fatigue crack initiation. Stress redistribution and higher crack thresholds contribute to enhanced fatigue resistance in SiC TPMS GCLSs.

Laser shock peening for enhanced fatigue resistance in steel structures: Insights from Q960 steel study

Fatigue damage of steel structures is often likened to the “cancer” of structural engineering. Fatigue failure, characterized by the absence of apparent signs before occurrence, usually leads to significant losses. To investigate the potential of laser shock peening (LSP) as an effective method for improving the fatigue performance of steel structures, square plates and compact tension (CT) specimens made of Q960 structural steel were designed. The surface integrity, fatigue crack growth (FCG) performance, microstructural grain size, and fracture morphology of specimens were compared at different laser shock parameters. The results show that LSP implanted a high level of beneficial residual compressive stress in a mild way, and no obvious surface defects were introduced. A noticeable retardation effect was found in the FCG of LSPed specimens, and this effect becomes more pronounced with the increase of laser pulse energy. Compressive residual stress is a more dominant factor in enhancing fatigue performance compared to grain refinement for the small-grained metals studied. LSP can effectively reduce the FCG rate of Q960 high-strength steel, showing promising application prospects in strengthening the fatigue hazard zone of steel structures.

A bioinspired polymer composite with tough, fatigue-resistant adhesion, and high interfacial thermal conductance via interfacial crosslinking

Achieving tough, fatigue-resistant adhesion and high interfacial thermal conductance (ITC) is crucial in various applications such as electronic packaging, soft electronics, and batteries, yet challenging. Herein, inspired by the tendon to bone adhesion, we present a polymer composite fabricated by incorporating interfacial crosslinking of boronic ester into commercially available polybutadiene that bind with fillers and various substrates. We demonstrate that fillers and interfacial crosslinking can enhance adhesion and ITC while also hindering crack propagation, resulting in enhanced fatigue resistance adhesion. Therefore, the fabricated composite exhibits excellent adhesion strength (12.07 MPa), ultra-tough adhesion (5885.85 J m−2), adhesion fatigue threshold (1377.23 J m−2), together with high ITC (118.4 MW m−2 K−1). We also demonstrate that the linear correlation between ITC and the adhesion fatigue threshold surpasses the relationship with adhesion strength and adhesion energy. In addition, the prepared polymer composite shows effective heat dissipation for electronic devices in various working conditions. It is anticipated that our research will stimulate the conceptualization and utilization of a diverse array of composite materials, including high-performance adhesives and polymer composites with high thermal conductivity.

Inelastic Cyclic Tests of Grade 80 (550 MPa) Bars with Mechanical Splices

This study addresses low-cycle fatigue performance of high-strength steel reinforcement bars (HSRB) when used with mechanical couplers due to the growing demand for higher-strength steel reinforcement bars in both seismic and non-seismic applications, driven by the need to reduce bar congestion, lower material quantities, and consider economic and environmental factors. Low-cycle fatigue involves material failure owing to a finite number of load or deformation cycles, generally occurring under substantial strain rates that surpasses the yielding limit. The experimental program assesses the fatigue behavior of HSRB produced using microalloying, quenching, and tempering techniques, coupled with mechanical couplers (eleven different types) from five companies in the United Stated of America. The study highlights significant differences in fatigue endurance based on the type and make of couplers and suggests potential improvements in manufacturing processes to enhance fatigue resistance. It is found that the mechanical couplers sustain a loading protocol of (-1% to 3%) when there is a clear distance of 2 times the diameter of the bar between the coupler and the gripping machine from top to bottom. The coupled bars sustained a minimum of 6 half cycles and a maximum of 38 half cycles.

Degree of bending of FRP-reinforced tubular X-joints in offshore jacket-type structures under in-plane bending moment

In offshore jacket structures, the stress within the chord thickness of tubular joints arises from both membrane and bending stresses. The Degree of Bending (DoB)—the ratio of bending stress to the total stress—is key to evaluating these joints' fatigue resistance. This study delves into the DoB in tubular X-joints reinforced with fiber-reinforced polymer (FRP) subjected to in-plane bending moment. It begins by validating finite element (FE) analysis accuracy through comparison with existing theoretical and experimental evidence. Following this, the analysis of 166 joints was conducted to examine how variations in FRP characteristics (such as type, layer count, and layout) and the joints' dimensionless geometric factors influence the DoB and its ratio in reinforced joints compared to their unreinforced counterparts. Findings indicate that FRP layers enhance fatigue resistance by lowering hot spot stresses on the chord's inner and outer surfaces and elevating the DoB value by up to 26.16%. Consequently, the study introduces a parametric formula for calculating the DoB in FRP-reinforced tubular X-joints under an in-plane bending moment. This development is significant, as there was no existing parametric formula for determining DoB in FRP-reinforced joints. The proposed formula stands out for its high determination coefficient and minimal error, effectively addressing a notable gap in the field.

A Review of the Studies on the Effect of Different Additives on the Fatigue Behavior of Asphalt Mixtures

The fatigue phenomenon significantly weakens road pavement due to repeated reloading. To enhance fatigue resistance, numerous studies have explored various additives in asphalt mixtures. This review focuses on key variables influencing the effectiveness of additives, including fibers, polymers, nanomaterials, waste materials, and biomaterials, in improving the fatigue performance of asphalt mixtures. The study initially identifies different additives and fatigue testing methods used for asphalt mixtures. It evaluates the impact of factors such as modifier content and size, base asphalt binder type, mixing processes, dispersion behavior, and testing conditions on the fatigue behavior of modified asphalt mixtures. The cost-effectiveness and environmental impact of additive application have also been assessed. Additionally, research gaps and future prospects for modified asphalt mixes are outlined. Existing studies demonstrate the benefits of additives like basalt fiber, polyester fiber, styrene–butadiene–styrene (SBS), nanosilica, crumb rubber, and biooils in enhancing the fatigue life of pavement constructions. However, challenges exist in the application of modifiers due to limited practical implications and insufficient knowledge. Further research is needed on factors such as additives’ dispersity, compatibility, aging resistance, economic viability, and modifying mechanisms in morphological and micromechanical aspects to enhance the fatigue performance of the modified asphalt mixture.

Enhanced fatigue resistance of ferroelectric Al0.65Sc0.35N deposited by physical vapor deposition

Enhanced fatigue resistance of ferroelectric Al0.65Sc0.35N deposited by physical vapor deposition

Carbohydrate Ingestion Increases Interstitial Glucose and Mitigates Neuromuscular Fatigue during Single-Leg Knee Extensions.

We aimed to investigate the neuromuscular contributions to enhanced fatigue resistance with carbohydrate (CHO) ingestion and to identify whether fatigue is associated with changes in interstitial glucose levels assessed using a continuous glucose monitor (CGM). Twelve healthy participants (six males, six females) performed isokinetic single-leg knee extensions (90°·s -1 ) at 20% of the maximal voluntary contraction (MVC) torque until MVC torque reached 60% of its initial value (i.e., task failure). Central and peripheral fatigue were evaluated every 15 min during the fatigue task using the interpolated twitch technique and electrically evoked torque. Using a single-blinded crossover design, participants ingested CHO (85 g sucrose per hour), or a placebo (PLA), at regular intervals during the fatigue task. Minute-by-minute interstitial glucose levels measured via CGM and whole blood glucose readings were obtained intermittently during the fatiguing task. CHO ingestion increased time to task failure over PLA (113 ± 69 vs 81 ± 49 min, mean ± SD; P < 0.001) and was associated with higher glycemia as measured by CGM (106 ± 18 vs 88 ± 10 mg·dL -1 , P < 0.001) and whole blood glucose sampling (104 ± 17 vs 89 ± 10 mg·dL -1 , P < 0.001). When assessing the values in the CHO condition at a similar time point to those at task failure in the PLA condition (i.e., ~81 min), MVC torque, percentage voluntary activation, and 10 Hz torque were all better preserved in the CHO versus PLA condition ( P < 0.05). Exogenous CHO intake mitigates neuromuscular fatigue at both the central and peripheral levels by raising glucose concentrations rather than by preventing hypoglycemia.

A comprehensive study on the effects of surface post-processing on fatigue performance of additively manufactured AlSi10Mg: An augmented machine learning perspective on experimental observations

In this study, the efficacy of 21 distinct surface post-processing methods on the fatigue behavior of an additively manufactured (AM) material was investigated. Various treatments, encompassing single-step processes like sand blasting (SB), conventional shot peening (CSP), severe shot peening (SSP), gradient severe shot peening (GSSP), ultrasonic shot peening (USP), severe vibratory peening (SVP), ultrasonic nanocrystal surface modification (UNSM), laser shock peening (LSP), laser polishing (LP), tumble finishing (TF), chemical polishing (CP), electro-chemical polishing (ECP), and machining (M), as well as hybrid treatments, were systematically investigated for their impact on the fatigue behavior of hourglass laser powder based fused (LB-PBF) AlSi10Mg specimens. A comprehensive series of experimental tests were carried out, covering surface texture analyses, microstructural characterizations, porosity measurements, hardness, residual stresses (RS), monotonic tensile tests, and rotating bending fatigue tests at four stress levels. Following the experimental investigations, the acquired data were leveraged to develop a machine learning (ML)-based model to correlate the fatigue life with the influencing factors and conduct parametric and sensitivity analyses. The model utilized a deep learning approach to predict the fatigue response of LB-PBF AlSi10Mg, incorporating various artificial neural networks (ANNs) and considering input parameters such as yield strength, ultimate tensile strength, elongation to fracture, porosity, depth of pore closure, surface hardness, depth of hardness variation, surface RS, maximum compressive residual stresses (CRS), depth of the CRS field, top surface grain size, surface layer mean grain size, surface roughness, and stress amplitude. Depending on the life regime, the factors influencing fatigue behavior can vary significantly. In higher stresses, dominated by plastic strains, surface residual stress emerges as the primary factor. Conversely, in lower stresses, dominated by elastic strains, the significance of surface roughness becomes more pronounced, followed by surface residual stress, surface hardness and other factors. These findings underscore the contextual importance of different influencing factors for enhancing fatigue resistance based on varying loading conditions.