Fatigue Life of Flywheel Energy Storage Rotors Composed of 30Cr2Ni4MoV Steel

In supporting the stable operation of high-penetration renewable energy grids, flywheel energy storage systems undergo frequent charge–discharge cycles, resulting in significant stress fluctuations in the rotor core. This paper investigates the fatigue life of flywheel energy storage rotors fabricated from 30Cr2Ni4MoV alloy steel, attempting to elucidate the material’s mechanical properties, crack propagation behavior, and impact of internal defects on fatigue life. Tensile tests reveal that the material exhibited high yield (992 MPa) and tensile strengths (1130 MPa). The Paris formula is used to model crack growth rates, ending in good agreement with the experimental data. Fatigue tests at various stress conditions highlight the material’s significant variability in fatigue life and emphasize the need for reliable design approaches. This paper also demonstrates that internal defect size and location critically affect fatigue life, calling for improvements in forging inspection standards. Overall, the present study provides a comprehensive analysis of 30Cr2Ni4MoV steel’s suitability for flywheel rotors, balancing safety, and operational efficiency.