• A novel damage sequence interaction model couples matrix and void phases to accurately predict residual mechanical properties of fatigued materials.
• Collision simulations show fatigue damage reduces vertical lift of moving metro vehicles by up to 9.17% and increases longitudinal compression of stationary vehicles by up to 33.15%.
• Experimental validation via trolley collision tests confirms the constitutive model's accuracy for engineering applications.
• The study underscores the necessity of incorporating fatigue damage in metro vehicle design and maintenance for enhanced safety.