Influence of build position on the fatigue performance of additively manufactured AlSi10Mg specimens of various heat treatments

This study explores the fatigue behavior of additively manufactured AlSi10Mg components under cyclic loading, with a specific focus on the influence of specimen position on the build platform (BP) on its fatigue life. Utilizing the well-established Laser Powder Bed Fusion (L-PBF) process—specifically the Concept Laser M2 system—experimental data collected over the past four years, including distinct S-N curves, have been used to identify regions of reduced fatigue performance across the build platform. To systematically investigate this spatial variation, each built platform was analyzed individually, with particular attention paid to unpredictable specimens and their precise locations on the print bed. A dedicated experimental platform of fatigue specimens was prepared, comprising 44 specimens divided into two groups of applied load levels. This setup enabled the first quantitative assessment of the correlation between spatial build position and fatigue strength in L-PBF-fabricated AlSi10Mg. In addition, four different heat treatment conditions were evaluated to understand their impact on fatigue resistance. Special emphasis was placed on the manufacturer-recommended thermal treatment for AlSi10Mg, providing a comprehensive perspective on the interplay between printing position, thermal processing, and fatigue performance. These findings offer critical insights for optimizing additive manufacturing strategies in demanding structural applications.