A Comprehensive Review on Fatigue Life Prediction Approaches for Additively Manufactured Components

Sushma Sahu; Hullash Chauhan

doi:10.36948/ijfmr.2025.v07i06.63507

A Comprehensive Review on Fatigue Life Prediction Approaches for Additively Manufactured Components

Author(s)	Ms. Sushma Sahu, Dr. Hullash Chauhan
Country	India
Abstract	The additive manufacturing (AM) has become a revolutionary fabrication process that can manufacture complex geometries, help cut down on weight, and simplify the prototyping process in various industries including aerospace, automobile, biomedical, and energy. Although significant improvements have been made in streamlining mechanical performance, the fatigue behaviour of AM components is still quite versatile in nature and in most instances, significantly worse than that of wrought counterparts. This is mostly explained by inherent defects in the processes, anisotropy of microstructures, surface roughness and unrelaxed deformation stress. As a result, fatigue life of AM structures to be used in safety-critical applications must be appropriately predicted to qualify and certify these structures. This is a systematically reviewed literature on state-of-the-art fatigue prediction methods of additively manufactured metallic parts. The reviewed methodologies include empirical S N curve based models, fracture based on the mechanics of crack-growth models, defect based prediction models, microstructure sensitive and crystal plasticity models, probabilistic reliability models, and emerging machine learning based methods. Major impacting parameters, such as defect morphology, pore distribution, post-processing, build orientation, and surface integrity are determined and critically analyzed. The review outlines the shortcomings of existing predictive models and suggests the combination of hybrid physics-based and data-driven to formulate a strategy to resolve shortcomings of existing predictive models to achieve standardized predictive methods applicable to industrial deployment. Future research directions emphasize the necessity of real-time defect trace monitoring, development of digital twins, and design of unified AM-specific fatigue design to be applied in order to enable safe and reliable performance in advanced engineering applications.
Keywords	Fatigue life prediction; Metal 3D printing; Fatigue crack growth; Defect-based modelling; Residual stresses; Surface roughness; Porosity; Microstructural anisotropy; Finite element simulation;
Field	Engineering
Published In	Volume 7, Issue 6, November-December 2025
Published On	2025-12-18
DOI	https://doi.org/10.36948/ijfmr.2025.v07i06.63507

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A Comprehensive Review on Fatigue Life Prediction Approaches for Additively Manufactured Components

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