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The flexibility in design offered by advanced additive manufacturing technologies makes these processes more and more attractive for automotive and aircraft applications and, also, for the production of safety relevant metal components. The high strength, thermally resistant nickel-based alloy Inconel®718 is widely used by the aircraft industry and its low level of machinability makes it an optimal candidate for AM technologies. The challenge, together with improving the process, is now to build the path that will bring AM technologies from rapid prototyping to series production. Therefore, it is essential to investigate additively manufactured materials and the effect that subsequent processing, such as, for example surface preparation, has on their properties. Furthermore, while the static properties of additively manufactured Inconel®718 have already been investigated, this work aims to describe its cyclic stress-strain behavior, which can be used for fatigue assessment.

Additive manufacturing offers new options for lightweight design for safety parts under cyclic loading conditions. In order to utilize all advantages and exploit the full potential of additive manufactured parts, the main impact factors on the cyclic material behavior not only have to be identified and quantified but also prepared for the numerical fatigue assessment. This means in case of the AlSi10Mg aluminum alloy to consider influences related to the exposure strategy, heat treatment, microstructure, support structures and the surface conditions, as well as the influence of the load history and finally the interaction of these influences in order to perform a high quality fatigue assessment. Due to these reasons, and with respect to the numerical effort, the cyclic material behavior of additively manufactured AlSi10Mg produced by selective laser melting will be discussed.