In this paper, numerical investigation was carried out to quantify the effect of the cold expansion on fatigue crack initiation in Aluminium alloy. The improvement in fatigue initiation life of specimen after the cold expansion process was investigated with the drilled hole of 2024 T351 Aluminium alloy plate. The applied degree of expansion (DCE%=100 (Dd)/d) is 4.6% where the effect of friction (µ=0.2) is considered. Residual stress field is determined using 3D Finite Element Analysis and shows the presence of compressive residual stress around the hole. The results showed a high compressive residual stress near the hole in exit face of the hole and at middle of the plate thickness around the hole. Local strain approach is applied in evaluation of fatigue initiation lives under Afgrow environment code. Fatigue initiation lives are improved by the presence of the compressive residual stresses comparatively to the drilled hole without of compressive residual stresses. Also, the fatigue initiation lives are increased with the increase in stress ratio for drilled hole and expanded hole Citation: El Habiri, Med., Benachour, M., Benachour, N., Effect of cold expansion on improving of fatigue initiation life of Aluminium alloy, Frattura ed Integrità Strutturale, 46 (2018) 34-44.