VHCF Behavior of SLM AlSi10Mg: Impact of Dual‐Laser Strategy and Fatigue Life Prediction

ABSTRACT The very high cycle fatigue (VHCF) behavior of AlSi10Mg specimens fabricated via selective laser melting (SLM) was systematically investigated under different printing strategies, including single‐laser and dual‐laser configurations. Experimental results revealed that fatigue cracks predominantly initiated at pores, with dual‐laser SLM specimens exhibiting significantly higher pore density and reduced fatigue life compared to single‐laser specimens. Among the examined factors, the depth of crack‐initiating defects relative to the specimen surface emerged as the most critical determinant of fatigue performance, surpassing pore size and aspect ratio. Furthermore, this study proposed an L model, which explicitly incorporates defect location and geometry effects, and demonstrated its superior predictive accuracy compared to classical models like Murakami's. These findings provide important insights for optimizing additive manufacturing process parameters to enhance the VHCF performance of SLM‐fabricated AlSi10Mg components.