The fatigue life curves of materials are very sensitive to the magnitude of the stress amplitude. A small change or inaccuracy in the determination of the stress value causes large changes or inaccuracies in the calculated fatigue life estimate. Therefore, the use of computer simulations for fatigue life estimation requires a proper model development methodology. The paper is devoted to the problem of the modeling of components in notches using FEM. The modeling parameters significantly influencing the obtained stress results have been defined. Exact analytical solutions served as a benchmark for comparing the accuracy of the stress values obtained using FEM models. For the selected 2D and 3D notched components, diagrams were created for sensitivity analysis of the influence of the mesh element density at the root of the notch in correlation with the exact analytical solution. The findings from model building were applied to model the stress concentration at the root of a V-weld joint in a gas pipeline.

Poisson’s ratio is one of the fundamental characteristics in the material models that are used. In engineering practice, its values are assumed to be constant in the elastic and in the plastic region. In this paper, the conventionally used values of this number for steel materials and aluminum alloys are confronted with experimental results. By using non-contact strain measurements with the DIC (digital image correlation) method, the evolution of the Poisson ratio value in the regions of transition from the elastic to the plastic region as well as in the regions of large plastic deformations was documented. The obtained experimental results are graphically compared using the proposed strain scaling. The gradient of the Poisson ratio changes in the vicinity of the yield stress is significant, indicating the need for a refinement of the material models in this region. Deviations from the conventionally used value of this number were found in the large plastic deformation region. In conclusion, a possible approach for improving the accuracy of simulations in FEM softwares was formulated.

Additive metals are practically identical in strength to the properties of conventionally produced materials. This article experimentally analyses strength properties and fatigue properties in the tensile–pressure mode for two different directions of 3D printing of AlSi₁₀Mg material. The resulting fatigue parameters of the Basquin curve are confronted with a conventionally produced alloy of the same composition. The microstructure analysis explains the different fatigue properties obtained by these two material production technologies. Phenomena such as strength enhancement in additive manufacturing material, anisotropy of cyclic properties, and cyclic hardening are discussed. The limits of current additive manufacturing are clarified, and the future direction of research in this field is outlined.