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<p>A failure analysis was performed on a fractured third-stage piston rod from a new hydrogen compressor, which failed after approximately 2750 hours of operation. The piston rod material (34CrNiMo6 steel) met standard specifications. Multi-scale characterization identified fatigue as the failure mechanism. The fracture surface exhibited fatigue initiation sites, central intergranular and cleavage features, and ductile dimples in the final rupture zone. Cracks initiated at stress concentration regions near sharp corners of residual alumina abrasive particles. These particles, embedded at the interface between the HVOF-sprayed WC-10Co-4Cr coating and the substrate, originated from grit blasting performed as a pretreatment. The residual alumina particles were identified as the primary cause of premature fatigue failure, as they reduced coating adhesion, diminished load-bearing capacity, and degraded coating wear resistance. A four-stage mechanism for the premature fatigue was proposed. The results highlight the critical influence of residual grit-blasting particles on both coating performance and component fatigue life. To mitigate such failures, it is recommended to optimize and strictly control grit-blasting parameters and to implement a post-treatment combining compressed air blowing and mechanical brushing. This ensures adequate substrate roughness and cleanliness, facilitating the deposition of high-quality, high-performance coatings.</p>

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Premature Fatigue Failure of Piston Rod in New Hydrogen Reciprocating Compressor

  • 期刊论文

  • 发表日期：

    2026年5月11日

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  • Yezheng Li,
  • Yiwei Huang,
  • Yongjun Li,
  • Hualin Chen,
  • Zongjian Feng,
  • Hanpeng Feng,
  • Jinlong Nong,
  • Xiaobin Zhang

摘要

A failure analysis was performed on a fractured third-stage piston rod from a new hydrogen compressor, which failed after approximately 2750 hours of operation. The piston rod material (34CrNiMo6 steel) met standard specifications. Multi-scale characterization identified fatigue as the failure mechanism. The fracture surface exhibited fatigue initiation sites, central intergranular and cleavage features, and ductile dimples in the final rupture zone. Cracks initiated at stress concentration regions near sharp corners of residual alumina abrasive particles. These particles, embedded at the interface between the HVOF-sprayed WC-10Co-4Cr coating and the substrate, originated from grit blasting performed as a pretreatment. The residual alumina particles were identified as the primary cause of premature fatigue failure, as they reduced coating adhesion, diminished load-bearing capacity, and degraded coating wear resistance. A four-stage mechanism for the premature fatigue was proposed. The results highlight the critical influence of residual grit-blasting particles on both coating performance and component fatigue life. To mitigate such failures, it is recommended to optimize and strictly control grit-blasting parameters and to implement a post-treatment combining compressed air blowing and mechanical brushing. This ensures adequate substrate roughness and cleanliness, facilitating the deposition of high-quality, high-performance coatings.