Fatigue design of Additive Manufacturing components through Topology Optimization: Comparison of methodologies based on the defect distribution and on the stress gradient

In this paper, the fatigue design of AM components is addressed through Topology Optimization. Two defect-driven methodologies, which model response in finite life range and account for experimental scatter, are compared. The first approach based on defect distribution marginal P-S-N curves. second method models size-effect by accounting stress within loaded material. two approaches used to assess maximum allowable principal stress, causes crack propagation. As strength depends component volume or distribution, an iterative procedure necessary determine optimal design. topologies a cantilever beam engine rod determined compared, showing that defect-distribution most conservative stress-gradient can also be reliably applied case uniform as rod. Furthermore, choice retain calculation critical.