| Abstract Scope |
Additive manufacturing (AM) techniques such as laser powder bed fusion (LPBF) produce engineering materials with unique microstructures and defects that must be carefully controlled to achieve optimal mechanical performance and damage tolerance beyond that of cast alloys. However, the relationship between processing parameters, micro-/mesostructure, and mechanical behavior—particularly crack resistance—remains poorly understood. In this study, we examine how key LPBF parameters, including layer thickness, hatch spacing, and scan strategy, affect tensile stress–strain behavior, crack resistance (R-curve), and fatigue crack growth in AlSi10Mg across different build orientations. We correlate these properties with structural features such as melt pool geometry, cellular morphology, grain size, orientation, and texture. Our findings show that processing variations significantly influence strength, fracture toughness, and fatigue performance. In particular, micro and mesostructural features shaped by LPBF settings play a critical role in governing the material’s resistance to deformation and failure. |