Performance Evaluation of Additively Manufactured Components under Cyclic Loading

Abstract

Additive manufacturing enables complex geometries and material-efficient production, but cyclic durability remains a central challenge for load-bearing components. Fatigue performance depends on the interaction between manufacturing defects, surface condition, microstructure, residual stress, geometry, and the applied loading history. This article presents a narrative review and an evaluation framework focused on metallic components produced by powder bed fusion. Nine dimensions are examined: process traceability, defect characterization, build orientation, surface integrity, post-processing, cyclic testing, fatigue-life modeling, statistical interpretation, and component-level qualification. The discussion distinguishes stress-life behavior, strain-controlled deformation, and fatigue crack growth because each addresses different stages and regimes of damage. A proposed assessment workflow links representative specimens with nondestructive inspection, fractography, mechanical modeling, and service-relevant validation. An illustrative stress-life graph uses explicitly assumed power-law coefficients to explain how specimen-condition differences may appear in fatigue data; it is not an experimental comparison or a source of design allowables. The review emphasizes that high tensile strength and high relative density alone do not establish satisfactory fatigue resistance. Reliable evaluation requires control of confounding variables, transparent treatment of runouts and scatter, and evidence that coupon results transfer to the actual component. Performance claims should remain specific to the alloy, manufacturing route, post-processing condition, geometry, and loading environment evaluated.