This article presents a failure analysis of an aluminum cylinder head on an automotive engine. During an endurance test, a crack initiated from the interior wall of a hole in the center of the cylinder head, then propagated through the entire thickness of the component. Metallurgical examination of the crack origin revealed that casting pores played a role in initiating the crack. Stress components, identified by finite element analysis, also played a role, particularly the stresses imposed by the bolt assembly leading to plastic strain. It was concluded that the failure can be prevented by eliminating the bolt hole,...