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<p>Penetrating cracks in rolled-steel (RS) surfaces during continuous aluminum casting can trigger premature brittle fracture, risking molten-metal leakage and serious accidents. This study employs fracture-mechanics principles and fractography analysis to elucidate how surface defects form and how multiple-small-fatigue cracks (MSFCs) initiate, propagate and coalesce on RS. Laboratory experiments reveal that the toughness and hardness of RS critically govern its fracture mode: low-toughness RS develops localized penetrating cracks, sharply reducing service life and elevating failure risk, whereas high-toughness RS allows MSFCs to evolve in a controlled manner, preserving structural integrity. These insights highlight the need to optimize RS mechanical properties as an effective preventive measure against brittle fracture in aluminum-casting applications.</p>

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Causes and prevention measures of brittle fracture of rolled steel due to heat-shrink-fitting process

  • 期刊论文

  • 发表日期：

    2026年3月10日

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  • Seung Hoon Nahm,
  • Hyusang Kwon,
  • Min-Soo Suh,
  • Chang-Min Suh

摘要

Penetrating cracks in rolled-steel (RS) surfaces during continuous aluminum casting can trigger premature brittle fracture, risking molten-metal leakage and serious accidents. This study employs fracture-mechanics principles and fractography analysis to elucidate how surface defects form and how multiple-small-fatigue cracks (MSFCs) initiate, propagate and coalesce on RS. Laboratory experiments reveal that the toughness and hardness of RS critically govern its fracture mode: low-toughness RS develops localized penetrating cracks, sharply reducing service life and elevating failure risk, whereas high-toughness RS allows MSFCs to evolve in a controlled manner, preserving structural integrity. These insights highlight the need to optimize RS mechanical properties as an effective preventive measure against brittle fracture in aluminum-casting applications.