Why this test matters
Residual stresses can remain locked inside metal components after manufacturing processes such as welding, forming, machining, or heat treatment. Left undetected, these stresses can cause distortion, reduce fatigue life, or trigger unexpected cracking during service. Residual stress measurement reveals exactly how much stress is locked into your part, and where, so you can catch a problem before it leads to failure. It applies to iron and steel, aluminium alloys, titanium alloys, and nickel alloys, and matters most for components used in industries such as aerospace, automotive, energy, rail, and construction, where safety and long-term reliability depend on getting this right.
How the test works
We use X-ray diffraction to measure residual stress without applying any external load: X-rays are directed at the material, and shifts in the diffraction pattern as the angle sweeps across the surface reveal the elastic strain, from which we calculate the actual stress state. To map how stress changes with depth, we remove thin layers through electrochemical polishing between measurements, building a full stress-depth profile instead of a single surface reading. Because our equipment is portable and fully safe to operate, we can measure directly on your actual part, on-site, at full size and complexity, instead of requiring a test coupon or a cut-out piece. In a single day, we typically complete around 40 surface measurements on a steel part, or 3 to 4 full depth profiles.
What you learn from this test
You receive quantitative data on the magnitude and direction of residual stress at each measured location, and, where a depth profile is taken, how that stress changes below the surface. This lets you identify critical stress concentrations, evaluate how a manufacturing process such as welding or heat treatment actually affected your part, and validate whether a stress-relief treatment worked as intended. Because measurements can be taken directly on a finished, full-size, or complex-shaped part rather than a cut-out sample, the results reflect your actual component, giving you a confident basis for design decisions, quality assurance, and predicting how long a part will last in service.
