Failure Modes of Aluminum Components in AI Data Centers


Recommended Structure

1. Why Failures Appear Faster in AI Infrastructure

  • 24/7 high-load operation
  • Thermal cycling
  • Vibration and micro-movement

2. Corrosion: More Than a Material Issue

  • Galvanic corrosion
  • Humidity and cooling systems
  • Surface treatment limitations

3. Deformation & Fatigue

  • Rack distortion under uneven load
  • Long-term creep risks
  • Transportation-induced stress

4. Vibration & Resonance

  • Fan-induced vibration
  • Cable trays & structural coupling
  • Small deflections, big consequences

5. Design vs Manufacturing Responsibility

  • Where failures actually originate
  • Why drawings alone don’t prevent issues

Closing Thought

Most failures are not caused by bad aluminum —
but by unrealistic assumptions.

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