Testing method for residual stress in complex-shaped workpieces

When using conventional methods to test the residual stress of complex-shaped workpieces, they may be obstructed by the X-ray diffraction path. The Ψ offset method and the Ω offset method were residual stress testing methods specifically designed for complex-shaped workpieces without diffraction space, and the stress calculation was still based on the sin²ψ method. These two methods could avoid damaging the size and shape of complex workpieces, improving the accessibility of X-ray stress testing. Comparative tests were conducted on iron powder zero-stress standard samples, shot-peened high-stress standard samples, and welded components using the Ψ offset method, the Ω offset method, and the conventional method, which verified the consistency of the test results among the three methods.