Compressive Stress Research Articles

Study on shot peening strengthening 42CrMoA steel and its fretting wear properties

In order to improve the tribological properties of 42CrMoA steel, it was shot peened using different parameters. The surface morphology, residual stresses, hardness, and micromotor properties of the treated specimens were thoroughly evaluated. The results showed that it led to substantial plastic deformation, increased surface roughness, grain refinement, and introduction of residual compressive stresses. In addition, a significant increase in microhardness and depth of hardened layers on the specimen surfaces was observed. Furthermore, a positive correlation between the effect of the shot peening process and the peening duration was observed. As revealed by the investigation, the shot peening process not only advances the wear resistance of the specimens but also leads to a reduced wear volume compared to untreated specimens. Furthermore, this treatment triggers a shift in the wear mechanism from the predominant occurrence of severe adhesive wear, fatigue wear, and abrasive wear in untreated specimens to a predominant mode of abrasive wear, accompanied by a minor occurrence of adhesive wear.

Wet shot peening effects on surface integrity and very high cycle fatigue of TC17 titanium alloy

With the increasing reliability requirements of aerospace equipment, very high cycle fatigue of TC17 titanium alloy has gained significant attention. This study investigates the effects of different wet shot peening treatments on the surface integrity and very high cycle fatigue performance of TC17 titanium alloy, elucidating the underlying mechanisms. Experimental results show that wet shot peening exacerbates surface defects, increases roughness, creates a plastic deformation layer, and induces compressive residual stress and work hardening. The combined effect of these factors reduces the fatigue performance. However, post-peening polishing significantly enhances the very high cycle fatigue performance by reducing stress concentration from surface defects while retaining the beneficial effects of compressive residual stress. Therefore, polishing after wet shot peening is concluded to be the most effective method for improving the very high cycle fatigue performance of TC17 titanium alloy.

Investigating microstructure dynamics and strain rate sensitivity in gradient nanostructured AISI 304 L stainless steel: TEM and nanoindentation insights

In recent years, gradient nanostructured (GNS) materials have gained significant attention due to their superior strength-ductility balance and enhanced functional properties compared to their coarse-grained counterparts. This research examines the microstructure evolution and nanomechanical responses of GNS AISI 304 L austenitic stainless steel using transmission electron microscopy (TEM) and nanoindentation techniques. Through surface mechanical attrition treatment (SMAT), a gradient nanostructured layer with ultrafine grains (∼15 nm) and nanoscale martensite (up to ∼40 %) within the austenite matrix has been successfully created on the steel’s surface. This treated surface exhibits a hardness of ∼6.7 GPa, nearly double the original value. The GNS layer demonstrates single-step (γ → α’) and two-step (γ → ε → α’) martensitic transformations, deformation twinning (γ -twin), a decrease in the density of deformation bands, compressive residual stress, lattice strain, and martensite content, along with an increase in grain size. Strain rate sensitivity (SRS) increases with austenitic grain size and inversely correlates with martensite proportion as depth increases in the GNS layer. A significant amount of ultrafine martensite is primarily responsible for the limited SRS in the topmost layer.

Multiscale shear failure mechanisms within a prestrained composite

AbstractThe elastic fiber prestressing (EFP) technique has been developed to balance the thermal residual stress generated during curing of a polymeric composite, where continuous fibers were prestretched under either constant stress or constant strain throughout the curing process. The tension was only removed after the resin was fully cured. It has been demonstrated that EFP is able to enhance the shear properties of the composite, while the underlying mechanics is still unknown. Here, we investigated the multiscale shear failure mechanisms induced by the EFP within a carbon composite. A bespoke biaxial fiber prestressing rig was developed to apply biaxial tension to a plain‐weave carbon prepreg, where the constant strain‐based EFP method was employed to produce prestrained composites with different prestrain levels. Effects of EFP on macro‐scale shear failure were subsequently characterized through mechanical tests and micro‐morphological analysis. Both the micro‐ and meso‐scale representative volume element (RVE) finite element models were established and experimentally verified. These were then employed to reveal the underlying stress evolution mechanics induced by EFP. It is found that EFP would improve the shear performance of a composite by enhancing the fiber/matrix interfacial bonding strength. This attributes to the elastic strain recoveries of the prestrained fibers locked within a polymeric composite, which generate compressive stresses to counterbalance the external loading. The multiscale shear failure mechanisms were then proposed. These findings are expected to facilitate structural design and application of the EFP for aerospace composites.Highlights Biaxial tension is applied to produce prestrained woven composite. Prestrain effects on microstructural stress evolution mechanics are revealed. Multiscale shear failure mechanisms are proposed for prestrained composites.

A unified theory for predicting the compressive stress–strain curve of concrete block masonry

I-type internal structures are commonly present in concrete hollow block masonry. A unified theory based on I-type internal structures is proposed to analyze types of masonry systematically. In this unified theory, the I-type element represents the I-type internal structure; the equivalent frame is introduced to analyze the interaction between the block and grout; and the characteristic strength of mortar is employed to measure the performance of mortar in masonry. Each subtheory of the unified theory is independent, and the application scope of this theory can be expanded by adjusting the subtheories. The predictions of the unified theory for the compressive behaviors of fully grouted, partially grouted, and ungrouted masonry are well matched with the measured data. Through targeted adjustments, the prediction of this theory for special cases is also accurate. The calculation results suggest that the unified theory can effectively analyze different types of masonry with an I-type internal structure.

Process-induced stress tuning to improve linearity performance in AlGaN/GaN HEMTs with SiNx passivation

Strain engineering has proven to be a useful technique for enhancing the performance of many modern-day transistors. Stress engineering can also have a non-trivial effect on the performance of GaN HEMTs, which are devices of choice for high-power, high-frequency microwave applications. Process-induced stress can have a significant effect on AlGaN/GaN HEMT electrical characteristics in addition to the growth-induced strain present due to lattice constant mismatch between device layers. Understanding the true impact of process-induced strain on AlGaN/GaN HEMT microwave performance is highly necessary. This is especially the case for nonlinearity effects which affect the high-frequency performance of the device. To the best of our knowledge, there is no systematic report on the effect of nitride passivation-induced stress on AlGaN/GaN HEMT device linearity. This work uses a systematic combination of TCAD process simulation and device simulation to quantify the effect of process-induced stress on the device’s linearity. This work demonstrates that nonlinearity effects can be minimized through proper tuning of stress by varying design-dependent parameters such as the nitride layer thickness. The effect of stress on highly important linearity parameters of the device like gm, gm2, gm3, VIP2, VIP3, IIP3 and IMD3 is investigated in detail. Comparing the compressive-stress device to the no-stress and tensile-stress devices, we conclude that the compressive stress device has a max gm2 value that is 61% and 71% higher respectively. The max gm3 for compressive stress is 0.13 A V−3 whereas those for no-stress and tensile stress are 0.067 A V−3 and 0.045 A V−3 respectively. However, the voltage-variations of VIP2, and the VIP3 parameters which are derived from these gm values shows that the compressive stress case can help achieve overall better device linearity by stress tuning. This work also studies how the effect of process-induced stress on device linearity varies with the crucial gate length parameter.

On the evolution of β1/β′ coupled-structures in Mg–Y–Nd alloys: A simulation study

In magnesium alloys based on the Mg–Y–Nd system, the key strengthening precipitate phases, β1 and β′, often form coupled-structures, with β′ precipitates invariably attached to both ends of the β1. A question here is how the attached β′ precipitates evolve as the β1 lengthens within the solid magnesium matrix. To investigate this, this study uses a multi-scale model based on a three-dimensional phase field approach to simulate the evolution of β1 and β′ precipitates in a β1/β′ coupled-structure. The simulation results reveal that, during the evolution process, the β1 precipitate lengthens, while the attached β′ precipitates grow only at the side located along the direction of β1 extension and dissolves at the opposite side. This results in a visual effect where the β′ precipitates appear to “move” within the solid matrix. This phenomenon is governed by the interplay between chemical free energy and elastic strain energy. Chemical free energy promotes uniform growth of the β′ precipitates. However, the elastic strain energy, generated by the β′ precipitates and the stress field concentrated at the end of the β1 plate to which they are attached, favours growth of only one side of the β′ precipitates while causing dissolution at the other side. When the evolution of a coupled-structure is influenced by neighbouring coupled-structures, the evolution of β′ precipitates is strongly driven by the minimization of elastic strain energy. In general, the β′ precipitates tend to grow under tensile stress fields and dissolve under compressive stress fields.

Superior damage tolerance observed in interpenetrating phase composites composed of aperiodic lattice structures

Interpenetrating Phase Composite (IPC) metamaterials, based on lattice topologies, have garnered significant attention as advanced materials for structural applications. However, conventional IPCs, which rely on periodic lattice unit cells, are prone to catastrophic failure due to their global deformation modes. To overcome this limitation, we present a novel IPC design utilizing aperiodic truss unit cells, inspired by the elusive “Einstein” monotile pattern. Our concept is demonstrated through IPC 3D printed via polymer jetting, using a hard polymer as the lattice filler and a soft polymer as the matrix. The distinctive mechanical properties of IPCs are characterized through single and cyclic quasi-static compression testing. Our findings demonstrate that aperiodic IPCs enable progressive deformation with gradual compression stress plateaus. Additionally, aperiodic IPCs exhibit remarkable damage tolerance, retaining 67.59 % of residual energy absorption and 73.83 % of ultimate strength after multiple cyclic compressions up to 30 % strain. These mechanisms are attributed to the synergistic deformation of interconnected unit cells, which lead to self-adjusting plastic collapse, progressive displacement evolution and delocalized deformation. This aperiodic concept paves the way for developing high-performance cushioning protection materials.

Enhanced mechanical, tribological and corrosion properties of graphite and carbon nanotube-reinforced copper-based hybrid composites

Copper (Cu)-based hybrid composites were fabricated by powder metallurgy, incorporating Graphite (Gr) and Carbon nanotube (CNT) reinforcements at various fractions. The composites were formed using a cold pressing technique and subsequently sintered at various temperatures. The structural properties of the hybrid composites were evaluated using Scanning Electron Microscopy (SEM), Energy Dispersion Spectrum (EDX) and X-ray diffraction (XRD). Hardness, compression, wear and corrosion tests were performed to show the effect of the reinforcements. It was shown that the hardness of Gr and CNT reinforcements have significantly improved the properties of pure Cu. The Cu-Gr-2CNT hybrid composite, which was subjected to sintering at a temperature of 850°C, exhibited the highest level of hardness, showing a significant increase of 51.4% in comparison to the pure Cu sample. While the compressive stresses increased in the Cu matrix with the addition of Cu-Gr, it increased to 350 MPa with the addition of 2 wt% CNT. The hardness value exhibited a similar increase and was measured to be 122 HV in Cu-Gr-2CNT. During the wear tests, the coefficient of friction values fell by 9.2% for Cu-2CNT, by 3.88% for Cu-CNT, by 3.92% for Cu-Gr-2CNT, and by 5.27% for Cu-Gr-CNT, as compared to pure Cu. The comprehensive findings demonstrated that the tests and analyses yielded consistent results, and the utilization of various combinations of Gr and CNT reinforcements enhanced the mechanical, tribological, and corrosion resistance properties of the fabricated hybrid composites. Nevertheless, the combination of Cu-Gr-2CNT yielded the most advantageous outcomes.

The thermal responses of composite box girder bridges with corrugated steel webs under solar radiation

Owing to the direct exposure to complex atmospheric environments, the temperature field of composite box girder bridge with corrugated steel webs (CBGB-CSW) is likely non-uniformly distributed. Whereas, the current researches regarding the thermal responses of CBGB-CSW are insufficient, and the thermal responses of CBGB-CSW under solar radiation are still unknown. Therefore, this paper conducted a long-term temperature experiment on a scaled model to explore the temperature distribution characteristics in CBGB-CSW. Meanwhile, a three-dimensional thermal–mechanical coupling Finite Element (FE) model is established to simulate the temperature field in the experiment girder. The accuracy and effectiveness of the developed FE model has been verified by the measured temperature data. Therewith, the thermal responses (i.e., stress and displacement) of a full-scale continuous CBGB-CSW with a span of 150 m are numerically investigated. The results indicate that the maximum stresses always occur at the midspan section (with a depth of 5 m) of the continuous CBGB-CSW, and considerable concentrations of stress are observed in the steel-concrete junction. The maximum longitudinal tensile and compressive normal stresses within 0.4 m of the upper junction can reach 5.55 MPa and −8.46 MPa respectively, and those of the lower junction can reach 6.96 MPa and −7.05 MPa respectively. Besides, owing to the impacts of vertical and horizontal temperature gradients, significant displacements of the whole bridge can also be observed. The maximum vertical displacement (5.33 mm) of the CBGB-CSW is estimated at the top plate in the midspan, while the maximum horizontal displacement (0.74 mm) is estimated at the trough of the southern corrugated steel web in the midspan. Notably, the outcomes of this paper can provide some useful references for engineers and scholars to understand the thermal responses of the CBGB-CSW.

Programmable mechanical responses of a hybrid star-rhombus honeycomb based on digital design method

Hybrid honeycombs with programmable mechanical responses have received widespread attention due to their multifunctionality and superior mechanical properties. To improve the tunability of the hybrid honeycomb, a hybrid star-rhombus honeycomb (HSRH) is designed using a digital design method. Different coding strategies are obtained by programming the distribution position of the rhombic structure inside the star-shaped honeycomb. HSRH with different coding strategies are designed by coding “0″ (unreinforced structure) and “1″ (reinforced structure). The compressive stress, Poisson's ratio and energy absorption of HSRH are investigated by experiments and numerical simulations. The results show that HSRH produces ordered deformation in compression with multi-plateau characteristics. HSRH has superior energy absorption in the X direction than in the Y direction. The specific energy absorption can be regulated between 2.41 - 5.02 J/g and 1.57–4.29 J/g in the X and Y directions, respectively. HSRH with unidirectional and bidirectional filling strategies exhibit a double-plateau feature in the X and Y directions, while the HSRH with hierarchical filling strategies has a three-plateau feature in the X direction. The filling ratio plays a decisive role in the energy absorption of honeycomb and has a positive correlation with the energy absorption properties. Furthermore, diverse deformation modes can be customized by introducing pattern-coding strategies. The codable deformation mode and programmable energy absorption of the HSRH are achieved by controlling the filling ratio and coding strategy (i.e., coding the number and location of embedded rhombic structures). This study provides a digital method for the design of programmable hybrid honeycombs and facilitates their application in multi-tasking energy absorbers.

Mechanical evaluation of multi-continuous interpenetrating phase composites based on Schwarz Primitive cellular structure

Interpenetrating phase composites (IPCs) have been extensively promoted due to their robust mechanical properties. To further obtain the enhanced properties and elucidate the underlying mechanical mechanism, we designed and manufactured the tri-continuous IPCs by filling hyperelastic PDMS into a 3D-printed Schwarz Primitive (P) cellular skeleton based on the viscoplastic polymer. Subsequently, the compressive properties, cyclic properties, and relaxation properties of the IPCs were experimentally investigated. Results demonstrated that interpenetrating can improve the compressive properties, reduce the relaxation behavior, and weaken the cyclic softening effect. By incorporating a user material subroutine in simulations, we analyzed the deformation behaviors of P cellular material and IPCs. Through a combination of experimental observations and simulated outcomes, we refined our understanding of the deformation mechanism of IPCs. Our analysis revealed that filled PDMS played a positive role in enhancing the mechanical performance of TC-IPCs through three key mechanisms: Firstly, it shears part of the external load of TC-IPCs. Secondly, it astricts the bending deformation in the skeleton, thereby preventing the stress drop induced by buckling. Thirdly, the interaction between PDMS and P cellular skeleton puts them in compressive stress in tri-direction, enhancing the overall mechanical properties. These findings contribute to advancing the development and application of IPCs.

Influence of ultrasonic-assisted abrasive peening treatment on Ti-6Al-4V and OFHC Cu alloys

Numerous peening techniques exist can effectively modify the sample surface, although at the expense of severe surface damage and high capital investment. Ultrasonic-assisted abrasive peening (UAP) is a superior option that can peen the surface with minimal deterioration using a basic probe sonicator. In this paper, the influence of UAP parameters (i.e., beaker size and fluid volume, power, abrasive concentration, and time) on the surface integrity of Ti-6Al-4V and OFHC Cu was studied experimentally. The process is capable of inducing significant compressive residual stress at around 84 % and 280 % of yield strength in Ti-6Al-4V and OFHC Cu, respectively. The study examined the change in surface roughness (ΔRa), ΔRa = roughness before - roughness after peening. As peening intensities increase, ΔRa reaches +7 nm, showing a surface finish in Ti-6Al-4V. The dislocations density calculated from the Williamson-Hall equation exhibited a 20 and 4.5-fold augmentation in peened Ti-6Al-4V and OFHC Cu in comparison to their un-peened state. EBSD analysis revealed a 28 % and 40 % reduction in grain size in Ti-6Al-4V and OFHC Cu after peening. This work validates the efficacy of the proposed UAP technique and supports the selection of optimized UAP process parameters.

The Influence of Shot Peening Media on Surface Properties and Fatigue Behaviour of Aluminium Alloy 6082 T6

Shot peening is generally used to improve the fatigue performance of mechanical components. However, identifying the geometrical and mechanical characteristics of the shots that improve fatigue strength is still a challenging task, as there are many variables involved in the shot peening process. The present work addresses the effect of different shot media on the fatigue behaviour of an aluminium alloy 6082 T6. Four different shot types were used: silica microspheres, alumina shots, aluminium cut wire and zinc cut wire. Axial fatigue tests were carried out to obtain the Wöhler curves corresponding to each shot peening treatment. The surface properties of the shot-peened specimens, such as grain size, hardness, residual stress and roughness were measured to determine their effect on the fatigue results. The fatigue results revealed that silica and zinc shots increased significantly the fatigue life of the alloy, whereas alumina and aluminium shots reduced its fatigue strength. Almen intensities have shown to correlate well with grain refinement and strain hardening. However, better fatigue results were obtained with the shots that generated higher surface compressive residual stresses. It is believed that small and smooth shots are preferable to sharp and irregular ones, regardless of the Almen intensity or surface hardness attained with the latter.

Probing fretting wear behavior of gauge-changeable spline axle under rotational bending loads

The latest generation of gauge-changeable trains in China feature designs with their wheels and axles connected by spline couples and cylindrical fits. In comparison to the interference fitted wheelset, the spline axle with clearance fit is more prone to fretting damage. In this study, the stress distribution of spline axle was analyzed using finite element method. Then, a rotatory bending test on scaled wheel/axle samples was conducted to reveal the fretting wear behavior of the gauge-changeable axle. During traction, the contact stress of the spline peaks at 311 MPa on the tooth’s root side, with a corresponding relative slip of 14 μm. Fretting wear is observed in the spline axle, the damage zone of the wheel seat can be categorized into five bands (A–E), and severely damaged areas are covered with red-brown debris. Moreover, the main damage mechanism of untreated spline axle and surface-modified spline axle is delamination accompanied with oxidation. The improved properties of plasma nitriding and grease lubricant are attributed to the high surface hardness and residual compressive stress, as well as low frictional stress.

A novel shell-like structure Zn-5Mn alloy with high strength and high plasticity for degradable oil fracturing tools

Fracturing tools for oil and gas exploitation require high mechanical properties and degradability. Zn alloys are possible to have good mechanical properties and much lower cost than widely used rare-earth Mg alloys, so it is worthy to develop Zn alloys as alternative materials. In this paper, a novel shell-like microstructure of Zn-5Mn alloy has been realized by bottom circulating water cooling. MnZn9 phase appears by the first time in Zn-Mn alloys with Mn < 6.4 wt%. This phase leads to the formation of hard MnZn9/MnZn13 core/shell structure with a high volume fraction of 76 %, dispersed uniformly in soft Zn phase. The alloy has excellent compressive properties without fracture even when stress and strain reach 2776 MPa and 80 %, respectively. Its ultimate uniform compressive stress and strain are 865 MPa and 56 % respectively, beyond widely used dissoluble Mg alloys. Weight loss rate of the Zn-5Mn alloy is two times that of pure Zn, immersed in 3 wt% KCl solution at 93°C. The shell-like Zn-5Mn alloy provides guiding significance of applying Zn alloys in fracturing tools for oil and gas exploitation.

AUTOMATION OF MEASUREMENTS OF ENGINE HEAT CONSUMPTION IN THE LUBRICATION AND COOLING SYSTEMS

The paper presents the results of an intermediate stage of the study of heat transfer processes in high-speed diesel engines of the automotive tractor type at transient load discharge-load-injection modes, which are characteristic of this type of diesel engines. In such modes, as evidenced by the results of calculations of the thermal stress state of combustion chamber parts, in particular pistons, exhaust valves of the gas distribution mechanism, significant tensile and compressive stresses are observed compared to operation at steady-state conditions. This is the reason for the occurrence of defects in the form of cracks on the heat exchange surfaces of these parts, which limits the service life of automotive tractor engines. For a more detailed study of transient processes, as the main approach, it is proposed to use the well-known method of heat balance tests of a high-speed diesel engine, but with the involvement of automated processing of measurement results in digital form at steady-state and transient modes. It is proposed to focus on heat consumption, which is a component of the heat balance in the lubrication and cooling system. Without the use of automated information processing directly at the time of transient load shedding and load shedding, it is impossible to obtain such information on cooling and lubrication systems. Recording of transient heat transfer processes makes it possible to track the influence of engine operating parameters, the dynamics of the transient process depending on its duration, the initial and final steady-state modes between which the transition is being studied. In general, this way, it is possible to assess the adaptability of cooling and lubrication systems to heat dissipation during sudden changes in load, to avoid, or at least limit, the growth of thermal stresses. The publication presents a possible variant of the schematic solution of such a system for automated processing of the results of heat balance tests with the maximum use of equipment that is mass-produced and has already been used previously in heat balance tests.

Enhancing mechanical and thermal properties of polyvinyl alcohol/curdlan composite hydrogels and aerogels via freeze-casting technique

This study introduces a novel approach to fabricating polyvinyl alcohol (PVA)/curdlan (CURD) composite aerogels by employing the freeze-casting technique to achieve exceptional mechanical and thermal properties. Our research demonstrated that the formation of dual-network structure that combines the mechanical strength of PVA with the thermal stability of CURD. Scanning electron microscopy revealed a unique honeycomb-like cross-sectional morphology in the PVA/CURD aerogels. Notably, the PVA/CURD composite hydrogel demonstrated consistent compressive stress performance even after 50 compression cycles and exhibited minimal swelling (only 4%) when immersed in distilled water for 24hours. Furthermore, the aerogels exhibited varying swelling ratios in different pH environments, with a significant increase observed in acidic conditions. Thermal analysis confirmed the enhanced thermal stability of the composite aerogels, attributed to the incorporation of CURD. These findings suggest that PVA/CURD composite aerogels have promising applications in fields that require materials with robust mechanical and thermal endurance.

Experimental study on grinding process of Al-Mg2Si aluminum matrix composites

As an aluminum-based reinforcement, Mg2Si particles have excellent properties such as high hardness, high melting point, and high elastic modulus compared with other reinforcements and are widely used in aerospace and automobile fields. However, there is little research on the cutting mechanism of this material. In order to explore the surface grinding mechanism of Mg2Si/Al composites, Grinding simulation of low-volume fraction Mg2Si/Al composites was carried out by ABAQUS, and the influence of different positions of matrix and particle removal on the surface quality of Mg2Si/Al composites was expounded. The plane reverse grinding test was carried out by using CBN (boron nitride) grinding wheel. The L16(43) orthogonal test and three groups of single factor tests were designed. The orthogonal results show that the linear velocity of the grinding wheel has the greatest influence on the surface roughness, and the feed rate and grinding depth are significantly smaller. The range analysis shows that the optimal grinding parameters are: vs = 35 m/s, vw = 0.75 m/min, ap = 0.015 mm. The regression equation for surface roughness was established by using MATLAB. The single factor results show that the surface quality is obviously improved by increasing the linear velocity of the grinding wheel and reducing the feed rate and grinding depth through the observation of the morphology of the processed specimen. The analysis results show that defects such as pits, protrusions, burrs, and a small amount of fish-scale-like on the machined surface are mainly caused by the linear velocity of the grinding wheel, the pulling force of the grinding wheel, and the adhesion of the debris. The defects such as particle micro-cracks, particle pull-out, and matrix cracking on the subsurface, are mainly caused by the compressive stress of the grinding wheel and the stress concentration of the particles. The research results have guiding significance for future composite material cutting research and actual cutting processing.

Strained Au skin on Mesoporous Intermetallic AuCu3 Nanocoral for Electrocatalytic Conversion of Nitrate to Ammonia across a Wide Concentration Range.

Electrochemical nitrate reduction reaction (NitRR) uses nitrate from wastewater, offering a hopeful solution for environmental issues and ammonia production. Yet, varying nitrate levels in real wastewater greatly affect NitRR, slowing down its multi-step process. Herein, a multi-strategy approach was explored through the design of ordered mesoporous intermetallic AuCu3 nanocorals with ultrathin Au skin (meso-i-AuCu3@ultra-Au) as an efficient and concentration-versatile catalyst for NitRR. The highly penetrated structure, coupled with the compressive stress exerted on the skin layer, not only facilitates rapid electron/mass transfer, but also effectively modulates the surface electronic structure, addressing the concentration-dependent challenges encountered in practical NitRR process. As expected, the novel catalyst demonstrates outstanding NitRR activities and Faradaic efficiencies exceeding 95 % across a real and widespread concentration range (10-2000 mM). Notably, its performance at each concentration matched or exceeded that of the best-known catalyst designed for that concentration. Multiple operando spectroscopies unveiled the catalyst concurrently optimized the adsorption behavior of different intermediates (adsorbed *NOx and *H) while expediting the hydrogenation steps, leading to an efficient overall reduction process. Moreover, the catalyst also displays promising potential for use in ammonia production at industrial-relevant current densities and in conceptual zinc-nitrate batteries, serving trifunctional nitrate conversion, ammonia synthesis and power supply.