In this study, the fatigue characteristics of aluminum alloys and mechanical components were investigated. To evaluate the effect of forging, fatigue specimens with the same chemical compositions were prepared from billets and forged mechanical components. To evaluate the cleanliness of the aluminum alloys, the cross-sectional area of specimens was observed, and the maximum inclusion sizes were obtained using extreme value statistics. Rotary bending fatigue tests were performed, and the fracture surfaces of the specimens were analyzed. The results show that the forging process not only elevated the fatigue strength but also reduced the scatter of the fatigue life of aluminum alloys. The fatigue characteristics of C-specimens were obtained to develop finite-element method (FEM) models. With the intrinsic fatigue properties and strain–life approach, the FEM analysis results agreed well with the test results.

Currently, a scroll compressor is used in many industrial fields; hence, research on its reliability is important. The major loading type during operation is pressure. However, unexpected contact between scroll compressors typically occurs, and thus, the severe loading condition should be considered. To consider this condition, the study modified the scroll compressor’s structure to a C-type specimen. The study applied cyclic axial load in the specimen. The main objective of the study is to define a proper fatigue life method for the aluminium scroll compressor and proper finite element method (FEM) modeling. To define the method, the study included a case study for various parameters, such as mean stress effects. Furthermore, a crack propagation study is presented. In the study, the Darveaux method that considers the Bauschinger effect of ductile material is used. It is expected that the consideration of the parameters can help define the fatigue life assessment of an aluminium scroll compressor.