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This study aims to uncover the multiscale relations among geometry, surface finish, microstructure and fatigue properties of curved-surface AlSi10Mg parts fabricated by powder bed fusion (PBF) additive manufacturing.

This paper investigated the high-cycle tensile and bending fatigue behaviors of PBF-built AlSi10Mg parts with curved surfaces. Besides, the surface finish, porosity and microstructure around various curvatures were characterized. Meanwhile, the stress distributions of the fatigue specimens with curved surfaces under the dynamic tensile/bending loading were analyzed via theoretical analysis and ANSYS simulation.

The results showed that the as-built specimens with the smallest curvature exhibited the best surface quality, smallest grain sizes and thinnest grain boundaries. In addition, the tensile fatigue fracture occurred around the largest curvature position of fatigue specimens, which was consistent with the simulated fatigue safety factor results. Moreover, the bending fatigue specimens with the largest curvature presented the shortest fatigue life due to the highest bending and shear stresses along the loading direction.

So far, most studies have focused on the fatigue behavior of as-built AlSi10Mg parts with planar structures only. The investigation on fatigue properties of as-built AlSi10Mg parts with curved surfaces remains unexplored. This study provides new insights into the characterization and quantification of the fatigue performance of PBF-built metal parts with complex geometries, the knowledge of which can promote their adoption in real industries.