Advanced Characterization of Mechanical and Cyclic Fatigue Properties of 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 funda-mental to assess their mechanical and cyclic fatigue properties thor-oughly. This investigation is primarily for optimizing material utiliza-tion 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 aluminum cast materials under different loading ratios and elevated temperatures. This paper presents an analysis of the statistical and geometrical influences on various aluminum alloys, including AlSi10MnMg, AlSi7Mg0.3, and AlSi8Cu3Fe, produced via pressure die casting and gravity die casting (permanent mold casting), and sub-jected to different heat treatment techniques, namely 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.