The air radiator had been in service for more than 30 years until a notch failure occurred. In this paper, a rare notch failure is completely investigated by means of macroscopic and microscopic observations, microstructural inspection, chemical analysis, and residual stress test. The results show that the notch failure mode of the air radiator is attributed to high-cycle fatigue fracture, due to the welded lapping surfaces near the notch on both sides of the corrugated plate trough not being put onto one plane during the welding process. Therefore, in order to prevent or reduce possible tensile stress, it is recommended that the welded lapping surfaces be put onto one plane before welding.
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