Conventional-sized specimens have been well and widely applied in research on hydrogen embrittlement. However, when the limited-size core components (nozzles and valves, etc.) of hydrogen energy equipment are evaluated for service damage, traditional testing with conventional-sized samples is no longer applicable and micro-sample testing methods are required. In this paper, recent progress in the characterization of hydrogen embrittlement achieved via a small-sized sample tensile test, small punch test and nanoindentation test is reviewed. The commonly used geometries and dimensions of various small-sized specimens are first described and the in situ hydrogen-containing environment testing cases equipped with small-sized specimens are presented, proving the advantages of direct observations of hydrogen influences on the mechanical property and microstructure evolution. Then, the quantitative analysis of hydrogen embrittlement sensitivity involving a small punch test is discussed, with a focus on the comparisons of the hydrogen embrittlement index calculated using different definition methods. Finally, the nanoindentation test of investigation on the interaction between hydrogen and dislocation in metals and the effect of indentation strain rate are summarized. Furthermore, the specific research directions and applications of micro-size specimens for further investigation on hydrogen embrittlement are identified.

This paper presents a dislocation-based yield strength model for the nano-indentation size effect. The model is based on functional expressions involving the densities of statistically stored dislocations and geometrically necessary dislocations. A single-phase austenitic stainless steel (316L) and a ferrite-austenite dual-phase steel (2205) are used here as the case-study materials to validate the proposed model. Experimental testing and finite element modelling of nano-indentation of the two materials are presented. Experimental tests are performed in the indentation load range from 1000$\mathrm{ }\mathrm{\mu }\mathrm{N}$ to 10000$\mathrm{ }\mathrm{\mu }\mathrm{N}$ . For 2205 steel, finite element modelling is performed using a dual-phase microstructure-based model. It is shown that, with consideration of statistically stored dislocations and geometrically necessary dislocations, finite element modelling results can reproduce measured load–displacement curves and hence, the size effect, within an error range of about 5%.

In this study, a combined experimental and finite element modeling methodology (FEM) for a nanoindentation study is presented to quantitatively investigate the influence of hydrogen on the mechanical properties of ferrite and austenite in 2205 duplex stainless steel. The experimental results showed that, during hydrogen charging, the nano-hardness of ferrite and austenite gradually increased with time, showing a hydrogen-induced hardening phenomenon. After 3 h of hydrogen charging, the nano-hardness of both ferrite and austenite reached a saturation state, and the values of the nano-hardness of ferrite and austenite increased by 17.5% and 46.1%, respectively. FEM is employed by using a dual-phase microstructure-based model to reproduce nanoindentation load–displacement curves. To minimize the indentation size effect, an analytical correction model considering geometrically necessary dislocations (GNDs) was proposed. By considering GNDs, the errors between numerical predictions and experimental data reduced from about 50% to less than 5%.

The gear transmission system is a safety-critical component in rail transit, typically designed for a service life exceeding 20 years. Failure analysis of such systems remains a key focus for railway engineers. This study systematically investigates four representative cases of premature gear failure in high-speed trains using a standardized analytical procedure that includes visual inspection, chemical analysis, metallographic examination, scanning electron microscopy, and hardness testing. The results identify four primary root causes: subsurface slag inclusions in raw materials, inadequate heat treatment leading to a non-martensitic layer (∼60 μm) at the tooth root, grinding-induced temper burns (crescent-shaped "black spots") accompanied by a hardness drop of ∼100–150 HV, and insufficient lubrication. The interdependencies between these factors and failure mechanisms, e.g., fatigue cracking, spalling, and thermal scuffing, are analyzed. This work provides an evidence-based framework for improving gear reliability and proposes targeted countermeasures, such as ultrasonic inclusion screening and real-time grinding temperature control, to extend operational lifespans.

This study investigates premature fatigue failures in three EA1N steel axles from permanent magnet direct-drive locomotives during wheel-seat bending tests. Complete fracture occurred in one axle at 3 million cycles, and in the other two axles, cracks appeared and were observed through magnetic particle detection at 3.5 million and 1.6 million cycles, respectively. A comprehensive failure analysis was conducted through metallurgical examination, fractography, mechanical testing, residual stress measurement, and finite element analysis. The fractographic results revealed fractures consistently initiated at the wheel-seat to axle-body transition arc, exhibiting characteristic ratchet marks and beach patterns. The premature fracture mechanism was identified as a high-stress fatigue fracture. The residual stress measurements showed detrimental tensile stresses at the surface. Coupled with the operating stress, the stress on the axle exceeds fatigue strength, which accelerates the initiation and propagation of fatigue cracks. Based on these observations, the failure mechanism was identified, and preventive methods were proposed to reduce the risk of recurrence of the in-service axles.

The utilization of micro-sample testing has demonstrated its effectiveness in conducting quantitative research on mechanical properties, damage evolutions and fracture features. For in-service equipment, millimicron sampling allows for non-destructive testing and analysis of mechanical performance evolution during operation. This paper presents a comparative study of the miniature uniaxial tensile test (MUTT) and small punch test (SPT) by experimental and finite element methods. As a comparison, the standard conventional-size tensile tests were also carried out. Detailed analyses of the elastoplastic behaviors and damage evolutions of MUTT and SPT were presented, followed by an application case illustrating the characterization of hydrogen embrittlement sensitivity based on MUTT and SPT. An inverse finite element modeling method of load–displacement curve reproduction was used to calibrate the variations of damage parameters of hydrogen-charged MUTT and SPT specimens. Hydrogen embrittlement (HE) indexes were determined by using different calculation methods. The results reveal that the HE sensitivity estimated by MUTT is higher than that measured by SPT, which is related to the different deformation processes and strain rates of the two testing methods.