Effect of Surface Finishing State on Fatigue Strength of Cast Aluminium and Steel Alloys

Matthias Oberreiter, Michael Horvath, Michael Stoschka, Stefan Fladischer

Research output: Contribution to journalArticleResearchpeer-review


The endurance limit of structural mechanical components is affected by the residual stress state, which depends strongly on the manufacturing process. In general, compressive residual stresses tend to result in an increased fatigue strength. Post-manufacturing processes such as shot peening or vibratory finishing may achieve such a compressive residual stress state. But within complex components, manufacturing-process-based imperfections severely limit the fatigue strength. Thus, the interactions of imperfections, residual stress state and material strength are key aspects in fatigue design. In this work, cast steel and aluminium alloys are investigated, each of them in vibratory finished and polished surface condition. A layer-based fatigue assessment concept is extended towards stable effective mean stress state considering the elastic–plastic material behaviour. Murakami’s concept was applied to incorporate the effect of hardness change and residual stress state. Residual stress relaxation is determined by elastic–plastic simulations invoking a combined hardening model. If the effective stress ratio within the local layer-based fatigue strength is evaluated as critical distance value, a sound calculation of fatigue strength can be achieved. Summing up, the layer-based fatigue strength design is extended and features an enhanced understanding of the effective stabilized mean stress state during cyclic loading.
Original languageEnglish
Article number4755
Number of pages41
Journal Materials
Issue number13
Publication statusPublished - 30 Jun 2023

Bibliographical note

Publisher Copyright: © 2023 by the authors.


  • bulk defects
  • cast aluminium
  • cast steel
  • computed tomography
  • elastic–plastic behaviour
  • fatigue assessment
  • fracture mechanics
  • residual stress
  • surface defects
  • vibratory finishing

Cite this