Despite the rapid growth of additive manufacturing (AM) technologies, AM parts usually present relatively poor surface quality in as-built condition. This necessitates the application of customized post surface treatments to efficiently enhance the surface quality and alleviate the adverse effects of high surface roughness and extremely irregular surface morphology on fatigue strength of AM metallic materials. In this paper, starting from an as-built AM surface, a detailed numerical model is developed to effectively estimate the surface morphology of laser powder bed fusion (LPBF) AlSi10Mg specimens after shot peening. The obtained results are then incorporated into two analytical approaches to evaluate the fatigue strength of different series. The accuracy of the model is validated by comparisons made with experimental data obtained considering as-built and shot peened specimens both before and after heat treatment. The results demonstrate that the proposed hybrid approach can serve as a powerful package not only to determine the beneficial contribution of shot peening on the surface morphology of AM material but also to provide an accurate and rather reliable approximation of their fatigue strength.

尽管增材制造 (AM) 技术发展迅速，但增材制造零件在完工状态下通常表现出相对较差的表面质量。这需要应用定制的后表面处理，以有效提高表面质量，并减轻高表面粗糙度和极不规则的表面形貌对增材制造金属材料疲劳强度的不利影响。在本文中，从已建成的 AM 表面开始，开发了一个详细的数值模型，以有效估计喷丸处理后激光粉末床融合 (LPBF) AlSi10Mg 试样的表面形貌。然后将获得的结果结合到两种分析方法中，以评估不同系列的疲劳强度。通过与考虑到热处理前后的竣工和喷丸处理试样获得的实验数据进行比较，验证了模型的准确性。结果表明，所提出的混合方法可以作为一个强大的包，不仅可以确定喷丸强化对 AM 材料表面形态的有益贡献，而且还可以提供准确且相当可靠的疲劳强度近似值。