Ductile Fracture Mode Research Articles

Mechanical properties of Si(1−x)–C(x): strength and stiffness of materials using LAMMPS molecular dynamics simulation

This study investigated the mechanical properties (elastic modulus, tensile strength, yield strength, and toughness) of different percent C of silicon carbide (SiC) using molecular dynamics simulations via the large-scale atomic/molecular massively parallel simulator (LAMMPS) with the uniaxial tensile test at four strain rates: 0.1, 0.5, 1.0, and 5.0 m s−1, using the Tersoff potential. The simulation uses 20 × 20 × 20 atoms (108.6 Å × 108.6 Å × 108.6 Å) of the diamond cubic structure of Si, then carbon atoms were placed randomly at 5% intervals from 0–50 percent C. Results show improved mechanical properties when increasing percent C until peaking at 25%, before decreasing. This is caused by the shortest bond length at 25 percent C from the increase of Si=C using the radial distribution function analysis. Increasing the strain rate generally improves the mechanical properties of the material. The deformation mechanism shows that increasing (decreasing) strain rate generally results in multiple (lesser) failure points with a ductile (brittle) fracture mode.

Study on the effect of microstructure on toughness dispersion of X70 steel girth weld

The girth weld metal impact toughness would affect the safe operation of long transmission oil and gas pipeline. In order to further clarify toughness law of pipeline steel girth weld, the Charpy impact toughness of X70 steel girth weld at −10 °C was studied by standard impact method, and the impact energy range was determined to be 18–95 J. The impact energy range of girth welds varied significantly, and the toughness was discrete. The impact toughness of the different microstructures in the girth weld at −158 °C was studied by the small specimen impact test. The root weld metal mainly consisted of ferrite and a small amount of pearlite, and its impact toughness was low. The large effective grain size and dislocation density difference between large lath bainite (LB) and coarse granular bainite (GB) increased the strain heterogeneity during impact deformation. In fine GB, effective grain size reduction and uniform distribution of Martensite austenite (M–A) components reduced the local strain, resulting in more uniform deformation. Therefore, the sample with the fine GB had higher impact the toughness and ductile fracture mode. For the standard Charpy impact samples, the main reason for toughness dispersion was change of fine GB proportion. The fine GB proportions of P6-2, P3-3 and P3-2 were 46.7 %, 40.8 %, and 29.5 %, respectively. Simultaneously, the influence of position change on the impact energy was considered.

Tailoring Weldability for Microstructures in Laser-Welded Near-α Titanium Alloy: Insights on Mechanical Properties

With the development of lightweight aerospace structures, the use of the high-quality and efficient laser welding of near-α titanium alloys has received widespread attention and favor thanks to its superior comprehensive performance. The welding experiment of 3 mm thick TA15 titanium alloy was carried out by YAG laser welding, and the material weldability, microstructure, microhardness, and mechanical properties of welded joints were systematically studied. The results indicated that laser welding of TA15 titanium alloy can produce well-formed welded joints without defects such as cracks and porosity. The welded metal used was a typical basket-weave microstructure composed of a large number of α′ martensitic phases and a small number of high-temperature residual β phases, and the heat-affected zone was a staggered arrangement of undissolved α phase and needle-like α′ martensite. The microhardness of the welded joint showed a hump distribution, and the hardness of WM fluctuated between 410 and 450 HV since the martensitic transformation occurred during the solidification of the weld under thermal cycling, and the β phase changed to the needle-like α′ phase. The tensile test indicated that the fracture position was located in the base metal area, and the fracture morphology showed the equiaxial dimple morphology of different sizes in a ductile fracture mode. The welded metal had the lowest impact performance (average value of 5.3 J) because the weld area was predominantly coarse α′ martensite. This experiment conducted systematic, in-depth, and extensive research on welding processes, hardness, tensile, impact, and fracture mechanisms. Based on the special product applications in the aerospace field, it was more targeted and conducive to promoting the application of the welding process in this material.

Numerical and experimental studies on dissimilar joining of Hastelloy C-276 and SS-316L using microwave hybrid heating at 2.45 GHz

Dissimilar joints of SS-316L and C-276 (Hastelloy) were developed using C-276 powder with microwave exposure 600 s in microwave applicator (2.45 GHz, 900 W). A multi-physics model was validated with experimental studies and simulation were carried out to analyse the microwave-joint interaction characteristics. The simulation results showed that a concentrated electric field (5.86 × 104 V/m) and higher resistive losses (3.07 × 107 W/m3) at the joint region facilitated rapid heat generation locally. Microstructural characterization of the joint revealed the formation of cellular grains such as Fe-Ni intermetallic phases with Mo, Cr and W-carbides along the grain boundaries. Joints exhibited average microhardness of 290 HV, and tensile strength of 425 ± 10 MPa and 14% elongation with failure due to both ductile and brittle fracture modes.

Revealing the failure mechanism of industrial Fe-25Cr-20Ni stainless steel plate: Fine-grained segregation band and brittle phase induced delamination cracking

The use of heat-resistant stainless steel thick plates in industrial production often presents challenges due to the presence of uneven microstructure and segregation, which can pose a persistent challenge for the prolonged safe operation of critical components made from such materials. This study aimed to investigate the fracture mechanism of an industrial Fe-25Cr-20Ni stainless steel plate at room temperature through uniaxial tensile experiments and fully reversed strain-controlled tension-compression fatigue experiments. Delamination cracks were observed on the fracture surfaces of both experiments. The specimens with fracture delamination were systematically studied by detailed microstructural evolution, and the failure mechanism and main reasons of fracture delamination were analyzed. The results show that the fracture delamination is related to the fine-grained segregation band (FGSB) consisted of fine grains and sigma phase located at the center of the thickness of the stainless-steel plate. The FGSB demonstrates low transgranular and intergranular fracture modes and exhibits bamboo knobs crack during plastic deformation, leading to a mixed fracture mode of ductile and brittle fracture. Furthermore, FGSB, as an anisotropic microstructure, which has a high stress concentration with nearby grains during plastic deformation. The sigma phase fracture and the weakening of the interface strength of the microstructure in FGSB provide a potential initiation site for fatigue crack initiation, thereby contributing to the possibility of aggravating fatigue damage and deteriorating fatigue performance. It is concluded that FGSB, as a metallurgical defect in stainless steel plates, is responsible for delamination failure.

Effects of heat treatments on the microstructure and mechanical properties of Inconel 718 alloy fabricated by electron beam freeform fabrication

The present study investigated the effects of different heat treatments on the microstructure and mechanical properties of Inconel 718 alloy fabricated by electron beam freeform fabrication. The Laves phases, γʹ phases, and (Nb,Ti)C particles were precipitated in the as-deposited specimen. Solution at 960 °C promoted the partial dissolution of Laves phases and the precipitation of δ phases. Further increasing the solution temperature to 1060 °C dissolved the Laves phases effectively, facilitating the adequate precipitation and uniform distribution of γʹ and γʹʹ phases during the subsequent double aging heat treatment. The ultimate tensile strength (UTS) and elongation of the as-deposited specimen were 770 MPa and 12.2 % respectively. The solution heat treatment at 1060 °C increased the elongation to 38.1 % but decreased the UTS to 734 MPa. The microhardness and UTS of specimens that underwent double aging heat treatment were significantly increased, with the maximum average microhardness and UTS reaching 491 HV0.5 and 1285 MPa, respectively. The undissolved Laves phases and the precipitated δ phases at grain boundaries impaired the ductility. The transformation from single solution or double aging heat treatment to solution plus double aging heat treatment led to a shift from a ductile fracture mode to a mixed ductile and brittle fracture mode.

Effect of Ti micro-addition on the hot tensile behaviour, microstructure and fractography of low-C high-manganese steels

The aim of the work was to determine the effect of Ti micro-addition on the hot tensile behaviour, microstructure and fractography of two low-C high-manganese steels with additions of Si and Al. The hot tensile tests were performed using the Gleeble 3800 thermomechanical simulator. Samples were stretched at a temperature range from 1050 ℃ to 1200 ℃ at a strain rate of 2.5·10 3 s−1. The microstructure of the tested high-manganese steels under conditions of hot deformation was influenced by strain hardening and simultaneous dynamic recrystallization, as well as precipitation processes-depending on the chemical composition of the alloy and plastic deformation parameters. The analysis of the curves registered in the hot tensile tests indicated that a decrease of strain hardening was the result of the dynamic recrystallization. Hot tensile curves of the Ti-micro-alloyed steel were characterized by higher yield stress compared to the Ti-free steel. The Ti micro-addition with a concentration of 0.075 wt.% guaranteeing stable TiN-type nitrides eliminated the possibility of precipitating AlN-type nitrides and complex MnS-AlN type non-metallic inclusions, which are harmful to hot ductility. Fracture modes of the Ti-free steel showed a mixed nature from 1050 ℃ to 1150 °C, i.e. ductile fracture and numerous cavities and voids were identified. As the deformation temperature increased to 1200 °C, the fracture character was brittle with numerous inter-crystalline cracks along austenite grain boundaries. The addition of Ti improved significantly the hot ductility behaviour characterized by higher values of flow stress and reduction in area as well as ductile fracture modes in the entire high deformation temperature range.

Microstructure, mechanical, and wear properties evaluation of Al-Cu based composite using RHA as reinforcement

ABSTRACT This study utilised a two-step stir-cast technique to fabricate Aluminium-based composites reinforced with 5% wt Copper (Cu) and varying weight percentages (1–4% wt) of Rice husk ash (RHA). Our work investigated the role of RHA reinforcement on the microstructure, mechanical properties, and wear characteristics of AlCuRHA composite. Characterisation of the composites and fracture surfaces was performed utilising SEM. The hardness and tensile properties were evaluated. Wear was conducted on the composites in dry and wet conditions using H2SO4 as the medium. The microstructure revealed the homogeneous distribution of the RHA within the AlCu matrix. The hardness of reinforced AlCu is enhanced from 54.24 Hv to 122.74 Hv with an increment of RHA reinforcement from 0 to 4%. The Ultimate tensile (UTS) and specific strengths were noted to increase with increased RHA content from 1 to 4% wt. The ductility levels were reduced with the increase in RHA content. The RHA-reinforced AlCu composite exhibits mixed ductile and brittle fracture modes. The composites with RHA exhibited greater wear resistance. Compared to the dry condition, the composites exhibited improved wear resistance in the acidic environment. The composite with 4 wt% RHA exhibited the lowest wear rates regardless of the environment.

Optimization of the grain boundary network and tensile properties of powder metallurgy-hot isostatic pressed Ni-based alloy Inconel 625

Powder metallurgy-hot isostatic pressing (PM-HIPing) is an advanced manufacturing technology for large-sized and complex-shaped components for nuclear applications. In the present study, a novel PM-HIPing strategy was proposed to optimize the grain boundary network and tensile properties of Ni-based alloy Inconel 625, and it was verified by a series of experiments. Samples with 69 % and 74 % of coincidence site lattice (CSL) grain boundaries were obtained when the narrow-size ranged powder was consolidated at 1140 °C and 1180 °C, respectively. The fraction of CSL grain boundaries was further increased to ∼78.5 % after a high temperature solution treatment. Room temperature yield strength and ultimate tensile strength of PM-HIPed alloy 625 were comparable to that of the wrought specimens, elongation of the specimens was ∼56–60 %, the samples all featured with dimple ductile dominant fracture mode.

Stepwise double-sided friction stir welding: an alternative for root defect mitigation in aluminium plates with lower gauge numbers

Penetration-induced fractional unbonded defects and flow-induced root flaws are part of the discontinuities of the conventional friction stir welded (FSW’ed) aluminium alloys with limited impact assessment/clarification in literature. The novelty of this study lies in the attempt to eliminate penetration-aided root defect via a stepwise double-sided welding process as well as identify its impact on loadbearing. As a result, the stepwise double-sided FSW welding of a thick aluminium plate (6 mm) was carried out while the microstructure, strength, and fracture modes of the ensuing welds were compared with the conventional (single-sided) friction stir welded counterparts. The stepwise double-sided FSW-welded joint demonstrated better tensile strength relative to the single-sided FSW-welded counterparts owing to its material flow consolidation (two-side deformation) and elimination of penetration-induced fractional unbonded region/root defect. The welding processes do not have a noteworthy influence on the fracture location of the welds as failure ensued via the stir zones of the respective welds. Transient breaking/brittle appearance, and ductile fracture modes were noticed in the single-sided and stepwise double-sided FSW-welded samples respectively. The stepwise double-sided FSW process is recommended as a better choice for thick workpieces relative to conventional FSW to improve the weld’s loadbearing resistance.

Investigation on the joining process and strength of laser circle welding between Al5052 and CFRP dissimilar materials

Laser welding is an effective approach to joining metal and composite. In the present research, laser circle welding was proposed to join the Al5052 sheet and PA6-CFRP as the first try. A process window was suggested according to the welding results and joint appearance. Single lap shear test was employed to evaluate the mechanical performance of welded joints under different welding conditions. The cross-section and fracture surface were subjected to multi-scale characterizations to subdivide the joining zone and understand the joining process. The result showed that 10 sets in 18 groups of welding parameters can achieve successful bonding. The welding results can be classified into four categories: non-connected, aging-failing, effective-joining and burn-through. The joining zone of laser circle welding was divided into three subregions. The adhesive zone (AZ) presented an interfacial fracture while the local failing passed through plastics basement in cohesive (CZ). The overheating of CFRP generated decomposed zone (DZ). The signal peak of O-C=O bond disappeared in the entire joining zone on CFRP sheet and the intensity of carbide was significant in DZ. The laser circle welded joint presented brittle and ductile fracture modes, which were related to the joining zone component. The joining strength can reach about 656 ± 22 N, 2135 ± 331 N and 3223 ± 257 N under one-circle, double-circle and three-circle scanning, respectively. Increased scanning numbers can decrease the required laser power and improve joining strength by extending heating time, while it also increased the risk of burn-through.

Quasi-Isotropy Structure and Characteristics of the Ultrasonic-Assisted WAAM High-Toughness Al Alloy

Wire Arc Additive Manufacturing (WAAM) has emerged as a highly promising method for the production of large-scale metallic structures; nonetheless, the presence of microstructural inhomogeneities, anisotropic properties, and porosity defects within WAAM Al alloys has substantially hindered their broader application. To surmount these obstacles, ultrasonic-assisted WAAM was applied in the fabrication of thin-wall structures utilizing 7075 Al alloy. This study investigates the effects of ultrasonic-assisted Wire Arc Additive Manufacturing (WAAM) on the structural and mechanical properties of 7075 Al alloy specimens. Microstructural analysis showed a significant refinement in grain distribution, with the average grain size notably reduced, enhancing the material’s homogeneity. Porosity across the specimens was quantified, showing a decrease in values from the upper (0.02151) to the middle (0.01347) and lower sections (0.01785), correlating with the rapid cooling effects of WAAM. Mechanical testing revealed that ultrasonic application contributes to a consistent hardness pattern, with measurements averaging 70.71 HV0.1 horizontally and 71.23 HV0.1 vertically, and significantly impacts tensile strength; the horizontally oriented specimen exhibited a tensile strength of 236.03 MPa, a yield strength of 90.29 MPa, and an elongation of 31.10% compared to the vertically oriented specimen which showed reduced mechanical properties due to the presence of defects such as porosity and cracks. The fracture morphology analysis confirmed a predominantly ductile fracture mode, supported by the widespread distribution of dimples on the fracture surface. The integration of ultrasonic vibrations not only refined the grain structure but also modified the secondary phase distribution, enhancing the quasi-isotropic properties of the alloy. These results underline the potential of ultrasonic-assisted WAAM in improving the performance of the 7075 Al alloy for critical applications in the aerospace and automotive industries, suggesting a promising direction for future research and technological advancement in additive manufacturing processes.

Hybrid Fabrication of Cold Metal Transfer Additive Manufacturing and Laser Metal Deposition for Ti6Al4V: The Microstructure and Dynamic/Static Mechanical Properties.

The titanium alloy components utilized in the aviation field are typically large in size and possess complex structures. By utilizing multiple additive manufacturing processes, the precision and efficiency requirements of production can be met. We investigated the hybrid additive manufacturing of Ti-6Al-4V using a combination of cold metal transfer additive manufacturing (CMTAM) and laser metal deposition (LMD), as well as the feasibility of using the CMT-LMD hybrid additive manufacturing process for fabricating Ti-6Al-4V components. Microstructural examinations, tensile testing coupled with digital image correlation and dynamic compressive experiments (by the split Hopkinson pressure bar (SHPB) system) were employed to assess the parts. The results indicate that the interface of the LMD and CMTAM zone formed a compact metallurgical bonding. In the CMTAM and LMD zone, the prior-β grains exhibit epitaxial growth, forming columnar prior-β grains. Due to laser remelting, the CMT-LMD hybrid additive zone experiences grain refinement, resulting in equiaxed prior-β grains at the interface with an average grain size smaller than that of the CMTAM and LMD regions. The microstructures reveal significant differences in grain orientation and morphology among the zones, with distinct textures forming in each zone. In the CMT-LMD hybrid zone, due to interfacial strengthening, strain concentration occurs in the arc additive zone during tensile testing, leading to fracture on the CMTAM zone. Under high-strain-rate dynamic impact conditions, the LMD region exhibits ductile fracture, while the CMTAM zone demonstrates brittle fracture. The hybrid zone combines ductile and brittle fracture modes, and the CMT-LMD hybrid material exhibits superior dynamic impact performance compared to the single deposition zone.

In-situ hybridization of an epoxy resin using polyurethane and MXene nanoplatelets for thermally stable nanocomposites with improved strength and toughness

A novel ternary composite system has been developed by combining MXene nanoplatelets with pre-polyurethane (PU) and an epoxy (EP) resin through in-situ polymerization and solution blending. Our approach aims to enhance the strength and toughness of the EP matrix while maintaining its thermal stability. The strong compatibility between isocyanate-terminated PU and hydroxyl-terminated MXene with the resin was demonstrated through chemical grafting and hydrogen bonding processes. In this ternary composite, significant improvements were observed, including a 32 % increase in tensile strength, a 46.4 % increase in flexural strength, and a 13.4 % increase in fracture toughness, even at very low filler contents of 0.05 wt% for MXene and 1 wt% for PU. A thorough examination of the fractured surfaces revealed the underlying mechanisms responsible for the improved strength and toughness. These mechanisms involve a transition from a brittle to a ductile fracture mode, which can be attributed to the combined effects of thermoplastic toughness, strong chemical bonding between PU and EP, and crack-anchoring and bridging effects facilitated by MXene nanoplatelets. The results presented herein are relevant to a wide range of applications in aerospace, automotive, electronics and various other industries where durability and thermomechanical performance of materials are critical.

Effect of material position and tool offset on the microstructure and mechanical properties of friction stir welded AA7075/AZ31B with ultrasonic assistance

The primary focus of this study is to analyze how changes in material position and tool offset affect the microstructure and mechanical properties of dissimilar alloys (AA7075/AZ31B) joints. The study specifically examines these effects in normal and ultrasonic-assisted friction stir welded (UVaFSW) aluminum and magnesium-based joints. The experiment showed that the sound weld was achieved only when the AA7075 plate was placed on the advancing side (AS). The metallographic analysis showed that the use of ultrasonic vibration increased the flow of material in the nugget zone (NZ) and improved the length of interpenetration at the interface. Moreover, the intermetallic compound (IMC) layer thickness decreased throughout the interface during UVaFSW, improving joint strength. The maximum ultimate tensile strength was obtained at 1 mm tool-off condition for UVaFSW, i.e., 112.40 ± 7.24 MPa. Ultrasonic vibrations reduced the IMC thickness by up to 78 % at the middle of the joint interface. The fracture surface showed the ductile fracture mode in the case of UVaFSW compared to the FSW process. The current study establishes the framework for optimizing and controlling the welding process of dissimilar AA7075/AZ31B alloys, which possess considerable potential for use in the aviation industry.

Effect of Mo/Nb ratio variations on the microstructure and cryogenic impact toughness of NiCrMo deposited metals

Effects of varying the Mo/Nb (in weight percent) ratio in ENiCrMo-6-deposited metals on the microstructure and cryogenic impact toughness of the metals were investigated. When the Mo/Nb ratio decreased from 6.09 to 3.28, the Nb-rich phase on the grain boundaries was transformed from un-continuous precipitation to continuous precipitation, the area fraction and average size of the precipitates within the grains were significantly increased, and a eutectic-type Laves phase appeared. Although the austenitic matrix of the deposited metals indicated a ductile fracture mode, the precipitates significantly deteriorated the cryogenic impact toughness. As the average size and area fraction of the precipitates increased, the cryogenic impact value decreased significantly.

Fracture behavior and constitutive relations of Sn-3.0Ag-0.5Cu solder alloy at cryogenic temperature

The mechanical behavior, underlying fracture mechanism and constitutive relations of Sn-3.0Ag-0.5Cu (SAC305) solder alloy at cryogenic temperature through in-situ uniaxial tensile experiments were investigated over a wide temperature range of 293 K–77 K. The activation of deformation twin in the solder alloy contributes to improve the tensile strength and quasi-static toughness, and maintains the fracture elongation at 35–45% with the decline of ambient temperature. SAC305 solder alloy with a mixed mode of ductile and brittle fracture achieves the optimal balance of strength, ductility and toughness at 123 K, and the large mismatch between twins thickening rate (∼13 μm/s) and dislocation slip velocity (∼3.6 μm/s) finally leads to the brittle fracture at 77 K. In addition, Anand model as a unified viscoplastic constitutive law has been employed to describe the constitutive relations of SAC305 solder alloy and fails in fitting the stress-strain curves at invalid temperature below 233 K. Hollomon equation is conducted to perfectly characterize the constitutive relations of the alloy at temperatures lower than 233 K. The method for controlling the formation of deformation twins in the solder alloy and solder joints is really beneficial to solve the reliability problems for cryogenic electronics.

Enhancing friction stir welding efficiency through rotational speed adjustment: a microstructural and mechanical analysis of Al-Cu alloy

Friction stir welding (FSW) has gained prominence in the aerospace and automotive industries due to its ability to produce high-strength and defect-free welds in aluminum alloys. The present investigation focuses on the impact of different tool rotational speeds (such as 700 rpm, 900 rpm, 1100 rpm and 1300 rpm), on the microstructure and mechanical characteristics of friction stir welded Al-Cu alloys. With the use of optical microscopy, scanning electron microscopy (SEM), x-ray diffraction (XRD), and evaluations of hardness, tensile characteristics, and fracture behavior, a thorough analysis was carried out. The weld nugget zone contained significant changes in grain size and shape as a function of rotational speed, as shown by microstructural analysis. The grain structure gradually became more refined when the rotating speed was raised from 900 to 1500 rpm. According to SEM observations, at faster speeds, the weld zone showed fewer defects per unit area and better bonding properties, which might be attributed to better material flow and plastic deformation. The effect was further clarified by XRD analysis, which showed differences in phase composition with varying rotating speeds. Evaluations of the mechanical properties showed a significant relationship between rotating speed and the mechanical performance of the welds. Hardness measurements showed that as rotating speed increased, hardness levels gradually increased. Welds made at faster rotational speeds had better elongation and tensile qualities, according to tensile tests. Additionally, fracture behavior study revealed that higher rotational speed welds displayed a more ductile fracture mode, indicating increased toughness.

Wire arc additive manufacturing of functionally graded carbon steel - stainless steel 316L - Inconel 625: Microstructural characterization and mechanical behavior

This work utilized a gradient method of joining plain carbon steel to stainless steel 316 L and then to Inconel 625 using wire arc additive manufacturing. The research investigated the quality of Functionally Graded Materials (FGM) structure, continuity, defect formation, microstructure, and mechanical properties of gradient regions. The investigation showed a strong, defect-free metallurgical bond between plain carbon steel and stainless steel 316 L and stainless steel 316 L and Inconel 625. The microstructure of stainless steel 316 L resulted from the solid-state transformation of ferrite-austenite (FA), with a significant presence of delta ferrite in the austenite matrix. In Inconel 625, the Laves intermetallic phase formed discontinuously between dendritic arms due to the microsegregation of alloy elements like niobium and molybdenum during solidification. The hardness values of Inconel 625, stainless steel 316 L, and plain carbon steel were 194–257 HV, 171–178 HV, and 159–170 HV, respectively. The ultimate tensile strength, yield strength, and elongation were achieved at 487 ± 10 MPa, 300 ± 6 MPa, and 40 % ± 0.15, respectively. The tensile test samples failed on the plain carbon steel side, indicating higher tensile strength at the interface and a well-bonded joint between the two alloys. Small, homogeneous dimples on the fracture surface confirmed the ductile fracture mode. The research demonstrates the use of wire-arc additive manufacturing (WAAM) to fabricate gradient materials with the required properties.

Effect of Phenolic Resin Coating Thickness on Mechanical Properties and Corrosion Resistance of Metal Materials

In the realm of petrochemical and other industries, metal materials face threats such as impact and high-temperature electrochemical corrosion. Consequently, there has been significant attention towards organic coatings that effectively attenuate impact forces while simultaneously providing a barrier against corrosive agents. The thermosetting phenolic resin 2130, known for the facile curing process, exceptional thermal stability, water resistance, corrosion resistance, and superior mechanical properties post-curing, finds extensive applications in the field of coatings. To address the challenge of depositing a complete and uniform resin coating on complex workpieces, coatings with varying thicknesses on the surface of 304 stainless steel were deposited via rotary evaporation combined with long-term low-temperature drying. The relationship between coating thickness and mechanical properties, as well as corrosion resistance, was investigated and analyzed through a comprehensive approach involving mechanical testing, electrochemical analysis, and long-term service weight loss assessment. The results demonstrated that the coatings deposited on the metal surface exhibited excellent integrity and compactness. Moreover, an increase in coating thickness led to a significant reduction in material corrosion rate. The coatings exhibited excellent substrate adhesion and flexibility, thereby providing effective protection against impact on the metal substrate. The relationship between the thickness of the coating and the surface roughness was evident, while the flexibility of the coating first increased and then decreased with the increase of coating thickness. When the coating thickness was 7 μm, the maximum surface roughness of the coating measured 0.44 μm. Under these conditions, the impact toughness of the coating reached the peak, exhibiting a ductile fracture mode and showcasing superior comprehensive mechanical properties. The findings of this study will offer theoretical support for the investigation and formulation of resin coatings in subsequent industrial production.