Weld Residual Stress Calculator
A simplified tool for engineers and students to estimate the magnitude of tensile residual stresses in a weld based on material strength and joint restraint.
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The Hidden Enemy: Residual Stress
As a weld cools and contracts, it pulls on the surrounding metal. If the component is free to move, this results in distortion. If the component is held firmly in place (restrained), it cannot distort, so the pulling forces are locked inside the material as **residual stress**. These hidden stresses can be dangerously high, often reaching the yield strength of the material. When the service load is then applied, it adds to the already existing residual stress, which can lead to premature failure, stress corrosion cracking, or reduced fatigue life.