In this study, the fatigue life of AlSi10Mg alloy produced by the laser powder bed fusion (LPBF) method is investigated through an extensive experimental and methodological approach. Electron backscatter diffraction (EBSD) and scanning electron microscope (SEM) analyses were conducted to examine the microstructural features of the material. Micropillar tests were performed to assess the deformation and slip movement of dislocation systems, as well as to evaluate the critical resolved shear stress (CRSS), which is a crucial parameter influencing the deformation and fatigue performance of metallic materials. The experimental findings provide essential insights into the microstructural characteristics and mechanical behaviour of AlSi10Mg, forming a robust foundation for subsequent computational studies. Finally, the methodology of the physically-based modelling approach is explained together with the experimental data extraction to develop such a modelling approach. The more thorough explanation and implementation of the physically-based modelling approach will be brought in part B.

This study presents a comprehensive multi-scale simulation approach to investigate the fatigue behaviour of AlSi10Mg alloy produced by the laser powder bed fusion (LPBF) method. Fatigue crack initiation within the microstructure is modelled using the physically-based Tanaka-Mura equation, developed from electron backscatter diffraction (EBSD) and scanning electron microscope (SEM) data. The fatigue crack growth is analyzed using the NASGRO equation, allowing for a detailed simulation of both crack initiation and propagation. The total number of cycles for each stress amplitude is calculated by summing the cycles required for micro-crack initiation and long-crack propagation, resulting in the generation of fatigue life (S-N) curves. This simulation approach provides a thorough understanding of the material’s behaviour under cyclic loading, leveraging the microstructural insights obtained from experimental data.