Uniform fatigue damage tolerance assessment for additively manufactured and cast Al-Si alloys: An elastic-plastic fracture mechanical approach

•Influence of additively manufacturing and casting on microstructure and porosity characteristics as well as quasi-static and cyclic stress-strain behavior of Al-Si alloys.•Evaluation of Murakami-Noguchi approach and Shiozawa approach for fatigue limit and lifetime estimation, however, both approaches are not sufficient for AM Al-Si alloys.•Linking J integral (elastic-plastic fracture mechanics) including cyclic stress-strain curve by means of morrow parameter (K’, n’), defect size and position, stress amplitude and stress ratio.•New approach enables a uniform fatigue damage tolerance assessment of fatigue lifetime and limit for additively manufactured alsi10mg alloy as well as die-cast and sand-cast alsi7mg alloy.