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Fatigue investigations of two 4XXX0-series aluminum alloys (acc. PN-EN 1706) within a range of fewer than 104 cycles at a coefficient of cycle asymmetry of R = –1 were performed in the current paper. The so-called modified low-cycle test, which provided additional information concerning the fatigue life and strength of the tested alloys, was also performed. The obtained results were presented in the form of diagrams: stress amplitude σa – number of cycles before damage N. On the basis of the microscopic images of sample fractures, the influence of the observed casting defects on the decrease of cycle numbers at a given level of stress amplitude were analyzed. Based on the images and dimensions of the observed defects, stress intensity factor KI was analytically determined for each. Their numerical models were also made, and stress intensity factor KI was calculated by the finite element method (FEM).
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