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Abstract The cyclic deformation and damage behaviors of Al-Si piston alloys are comprehensively studied. It is found that the fatigue cracks mainly initiate from broken primary Si at low temperature and phase/matrix interface debonding at higher temperature. The transgranular crack propagation can be found for all the temperatures and the grain is obviously reduced after low-cycle fatigue at higher temperature. Furthermore, a hysteresis energy-based life prediction model was developed and utilized. Based on the model, the optimum fatigue life was found at intermediate temperature. A strategy for fatigue property optimization was proposed: increasing W0 at low temperature and increasing β at high temperature, to enhance the fatigue life during entire service temperatures with the ultrasonic melt treatment. In this way, the remarkable improvement of the fatigue properties may be achieved.

Property optimization of low-cycle fatigue in Al-Si piston alloy at elevated temperatures by ultrasonic melt treatment