PU foam, being thermoset, has no distinct fatigue limit. Under high-frequency (>100Hz), low-amplitude (±0.2mm) vibration, cell walls undergo repeated bending, generating micro-cracks that accumulate into a “fretting wear”-type fracture. Typical case: after 2000 hours of operation, the PU core of an engine soundproof cover turned from white to yellow, compressive modulus dropped by 40%, and localized delamination occurred between facing and core. Solutions: replace with PET sandwich panel (high fatigue limit

