The competing role of defects and surface roughness on the fatigue behavior of additively manufactured AlSi10Mg alloy
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Bibliographic record
Abstract
The fatigue behavior of AlSi10Mg alloy processed by laser-based powder bed fusion of metals (PBF-LB/M) in as-built (AB) and surface treated conditions, is assessed. A new chemo-mechanical polishing (CMP) surface treatment is applied to AB specimens to achieve an average surface roughness of S a ≈ 0.3 μm which is more than two orders of magnitude lower than that of AB specimens ( S a ≈ 48.6 μm). The CMP surface treatment led to a significant improvement in fatigue strength of the alloy as compared to the AB material. The fatigue life of AB + CMP specimens is discovered to be governed by surface or near surface defects, whereas the deepest surface roughness valleys play a dominant role in controlling the fatigue behavior of the AB material. A simplified fracture mechanics-based fatigue life modeling approach was developed by combining real-time defects distribution data from 3D computed tomography (CT) and surface profilometry measurements. The model provided a quick and effective medium for obtaining reasonable first-order fatigue life approximations for AlSi10Mg alloy fabricated using PBF-LB/M.
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Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.000 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.000 | 0.000 |
| Bibliometrics | 0.000 | 0.000 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.000 | 0.000 |
| Open science | 0.000 | 0.000 |
| Research integrity | 0.000 | 0.000 |
| Insufficient payload (model declined to judge) | 0.000 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from it