Advanced Characterization of Mechanical and Cyclic Fatigue Properties in Aluminum Cast Materials for Optimized Industrial Applications

Given the strategic importance of aluminum cast materials in producing lightweight, high-performance products across industries, it is crucial to assess their mechanical and cyclic fatigue properties thoroughly. This investigation is fundamental for optimizing material utilization and enhancing the efficiency and reliability of aluminum cast components, contributing to significant conservation of raw materials and energy throughout both the manufacturing process and the product's lifecycle. In this study, a systematic material investigation was conducted to establish a reliable estimation of the fatigue behavior of different alu-minum cast materials under different loading ratios and elevated tem-peratures. The analysis the statistical and geometrical influences on different aluminum alloys, including AlSi10MnMg, AlSi7Mg0.3, and AlSi8Cu3Fe, produced through pressure die casting and gravity die casting (permanent mold casting), with heat treatments T5, T6, and T7. Furthermore, to optimize component design, the effects of surface finish (machined versus unmachined with cast skin), temperature, and microstructural changes (e.g., secondary dendritic arm spacing) on fatigue strength were investigated and documented.