Enhancing The Fatigue Strength Of AM Materials Via Mechanical Surface Treatment

Additive manufacturing (AM) processes, while enabling the production of intricate geometries, frequently result in suboptimal surface quality, which can significantly restrict the fatigue strength of components when compared to those manufactured using traditional methods. This study explores the effectiveness of mechanical surface treatment (MST) techniques, specifically shot peening and deep rolling, in enhancing the fatigue performance of additively manufactured AlSi10Mg and 316L alloys. A combination of experimental investigations and finite element simulations was employed to evaluate the influence of these treatments on surface integrity, microstructure, and fatigue life. The results reveal that both MST approaches lead to substantial improvements in fatigue strength. Notably, for AlSi10Mg, there was an observed enhancement in fatigue strength of at least 20%, companied by a significant increase in the slope of the S-N curve by at least 50%. These findings highlight the potential of MST methods to effectively address surface defects and improve the overall durability and reliability of components produced through additive manufacturing, thereby expanding their applicability in demanding engineering fields.