A single batch of AlSi10Mg powder was used to fabricate two groups of round bars via horizontal printing, employing an identical strategy except for one parameter in the process of powder bed fusion-laser beam. The parameter is layer thickness, set at 50 and 80 μm for Group-1 and Group-2, respectively, resulting in laser energy densities of 29.95 and 18.72 J/mm³. Both materials exhibit similar microstructures; Group-1 has fewer and smaller defects than Group-2, leading to higher strength and ductility. Fatigue performance of low-cycle and long-life up to 10⁸ cycles under rotating bending was assessed, and the fracture surfaces were carefully examined under scanning electron microscopy. The S-N data converge to a single slope followed by a horizontal asymptote, indicating the occurrence of very-high-cycle fatigue (VHCF) in both cases. Group-1 shows higher fatigue strength in the range of 10⁴ to 10⁸ cycles, and a greater failure probability in VHCF regime than Group-2. This is attributed to the larger defect size in Group-2, where the smaller control volume in rotating bending greatly increases the likelihood of encountering large defects compared to Group-1. At the defect edge, the microstructure shows distinct resistance to crack propagation under high and low loads.

A single batch of AlSi10Mg powder was used to fabricate two groups of round bars via horizontal printing, employing an identical strategy except for one parameter in the process of powder bed fusion - laser beam. The parameter is layer thickness, set at 50 and 80 μm for Group-1 and Group-2, respectively, resulting in laser energy densities of 29.95 and 18.72 J/mm³. Both materials exhibit similar microstructures; Group-1 has fewer and smaller defects than Group-2, leading to higher strength and ductility. Fatigue performance of low-cycle and long-life up to 108 cycles under rotating bending was assessed, and the fracture surfaces were carefully examined under scanning electron microscopy. The S-N data converge to a single slope followed by a horizontal asymptote, indicating the occurrence of very-high-cycle fatigue (VHCF) in both cases. Group-1 shows higher fatigue strength in range of 104 to 108 cycles, and a greater failure probability in VHCF regime than Group-2. This is attributed to the larger defect size in Group-2, where the smaller control volume in rotating bending greatly increases the likelihood of encountering large defects compared to Group-1. At the defect edge, the microstructure shows distinct resistance to crack propagation under high and low loads.