Near-surface Stress Research Articles

Validation of Hole-Drilling Residual Stress Measurements in Workpieces of Various Thickness

BackgroundA recent revision to the ASTM E837 standard for near-surface residual stress measurement by the hole-drilling method describes a new thickness-dependent stress calculation procedure applicable to “thin” and “intermediate” workpieces for which strain versus depth response depends on workpiece thickness. This new calculation procedure differs from that of the prior standard, which applies only to thick workpieces with strain versus depth response independent of thickness.ObjectiveHerein we assess the new calculation procedures by performing hole-drilling residual stress measurements in samples with a range of thickness.MethodsNear-surface residual stress is measured in a thick aluminum plate containing near-surface residual stress from a uniform shot peening treatment, and in samples of different thickness removed from the plate at the peened surface. A finite element (FE) model is used to assess consistency between measured residual stress across the range of sample thickness.ResultsMeasured residual stress varies with sample thickness, with thinner samples exhibiting smaller near-surface compressive stress and a larger gradient of subsurface stress. These trends are consistent with both observed bending (curvature) of the removed samples and the trend in FE-calculated expected residual stress. The measured and expected residual stresses are in good agreement for samples of intermediate thickness, but the agreement decreases with sample thickness. Measured residual stress is invariant with gage circle diameter.ConclusionThe new thickness-dependent stress calculation procedure for hole-drilling provides meaningful improvement compared to thick-workpiece calculations.

Research on the correlation between roughness parameters and contact stress on tooth surfaces and its dominant characteristics

The contact performance of the tooth surface is a crucial factor affecting the operational lifespan of gears. There is a significant correlation between tooth surface topography and contact stress, as well as fatigue performance. To investigate the influence of different topography parameters on tooth surface contact stress, this paper performs analytical calculations on asperity contacts of rough tooth surfaces based on reconstruction modeling. Through efficient calculations, sufficient correlation analysis data is obtained. The neural network analysis method is used to measure the degree of influence of roughness parameters on tooth surface contact performance. Research on the correlation between micro-topography parameters and maximum contact stress on tooth surfaces, as well as regression analysis, is conducted. The results show that: (1) Considering rough surfaces, the tooth surface contact stress field exhibits two stress peaks in the near-surface layer and sub-surface layer, with a maximum Mises stress increase of up to 30 % compared to a smoother surface. (2) In the case of low roughness (Sa < 0.2 μm), the amplitude of the maximum Mises stress peak in the near-surface layer is close to that in the sub-surface layer. However, as the roughness amplitude increases, the amplitude of the near-surface stress peak increases sharply. (3) Ranking the roughness parameters based on their influence on contact stress, the main parameters characterizing contact performance are identified as Spk, Vmp, and Sq. The peak characteristics of the surface are the decisive factors affecting fatigue extremes, which are stronger than the traditional surface roughness parameter Sq. This paper establishes a direct correlation model between tooth surface topography parameters and contact stress, providing a foundation for simplifying stress calculations considering complex topographies and offering new insights for fatigue-resistant design of tooth surfaces.

Progressive Induction Hardening: Measurement and Alteration of Residual Stresses

Progressive induction hardening is an in-line steel heat treatment method commonly used to surface harden powertrain components. It produces a martensitic case layer with a sharp transition zone to the base material. This rapid process will induce large residual stresses, where a compressive state in the case layer will shift to a tensile state in the transition zone. For fatigue performance, it is important to quantify the magnitude and distribution of these stresses, and moreover how they depend on material and processing parameters. In this work, x-ray diffraction in combination with a layer removal method is used for efficient and robust quantification of the subsurface stress state, which combines electropolishing with either turning or milling. Characterization is done on C45E steel samples that were progressively induction hardened using either a fast or slow (27.5 or 5 mm/s, respectively) scanning speed. The results show that although the hardening procedures will meet arbitrary requirements on surface hardness, case depth and microstructure, the subsurface tensile stress peak magnitude is doubled when using a fast scanning speed. However, the near-surface compressive residual stresses are comparable. In addition, the subsurface tensile residual stress peak is compared with the on-surface tensile stresses in the fade-out zone.

Prediction of residual stress depth profiles in case-carburized gears

Residual stresses have a significant influence on the load carrying capacity of gears. High near-surface compressive residual stresses can increase pitting strength and tooth root bending strength up to 50%. Tooth flank fracture (TFF) is a gear fatigue failure mode, which is in contrast to pitting or tooth root breakage not initiated at the surface or close to the surface but in larger material depths beneath the active gear flank. Therefore, the residual stresses in larger material depths are decisive for TFF. In these larger material depths, the residual stress conditions are almost unknown up to now. It is assumed that tensile residual stresses are present in these areas, which can negatively influence the TFF load carrying capacity. So far, no validated methods are known to estimate or predict these tensile residual stresses. As a result, the tensile residual stresses could not be considered in the calculation methods for the risk of TFF at all until recently.This paper presents a method to predict the residual stresses in case-carburized gears based on comprehensive numerical simulations of case-carburizing processes of different-sized gears. The calculated residual stress profiles also consider the tensile residual stresses in larger material depths.

The 3D stress field of Nordland, northern Norway – insights from numerical modelling

Abstract The Nordland area in northern Norway is the seismically most active area on mainland Fennoscandia. It exhibits patterns of coastal extension, which contrasts with the first-order regional stress pattern that reflects compression aligned with the North Atlantic ridge push. The regional stress field has been considered to emanate from the interaction of ridge push and glacial isostatic adjustment; while the local stress pattern can be additionally influenced by gravitational, topographic stresses, as well as the flexural effects of erosion and sediment deposition. We employ finite element numerical models at a crustal scale to study the 3D stress field, using existing geometric constraints from previous geophysical studies. Internal body forces, induced by variations in density, topography or Moho depth, already yield significant deviatoric stresses. In the models tested, these can strongly influence the near-surface stress regime, in particular for the continental margin setting we are investigating. In addition, redistribution of rock mass, which occurred mainly under Pleistocene glaciation, can modify the stress field significantly on a semi-regional scale. We consider this process to be the main driver for the coastal extension, in particular in areas where erosion has been high.

Residual Stress Engineering for Wire Drawing of Austenitic Stainless Steel X5CrNi18-10 by Variation in Die Geometries-Effect of Drawing Speed and Process Temperature.

As a result of conventional wire-forming processes, the residual stress distribution in wires is frequently unfavorable for subsequent forming processes such as bending operations. High tensile residual stresses typically occur in the near-surface region of the wires and can limit further application and processability of the semi-finished products. This paper presents an approach for tailoring the residual stress distribution by modifying the forming process, especially with regard to the die geometry and the influence of the drawing velocity as well as the wire temperature. The aim is to mitigate the near-surface tensile residual stresses induced by the drawing process. Preliminary studies have shown that modifications in the forming zone of the dies have a significant impact on the plastic strain and deformation direction, and the approach can be applied to effectively reduce the process-induced near-surface residual stress distributions without affecting the diameter of the product geometry. In this first approach, the process variant using three different drawing die geometries was established for the metastable austenitic stainless steel X5CrNi18-10 (1.4301) using slow (20 mm/s) and fast (2000 mm/s) drawing velocities. The residual stress depth distributions were determined by means of incremental hole drilling. Complementary X-ray stress analysis was carried out to analyze the phase-specific residual stresses since strain-induced martensitic transformations occurred close to the surface as a consequence of the shear deformation and the frictional loading. This paper describes the setup of the drawing tools as well as the results of the experimental tests.

The Effect of Chemical Composition on the Microstructure and Properties of Multicomponent Nickel-Based Boride Layers Produced on C45 Steel by the Hybrid Method

Layers of iron–nickel Fe-Ni-B-type borides were produced on C45 steel using a new hybrid treatment variant which combines boriding under glow discharge conditions with galvanic nickel precoating. The aim was to investigate whether these layers could constitute an alternative to the previously developed multicomponent Fe-Ni-B-P-type layers produced by a hybrid treatment variant using chemical nickel precoating. The basis for assessing the effects of both alternative treatments was a comparative analysis of the microstructure and performance properties of three model boride layers: iron–nickel boride layers of the Fe-Ni-B and Fe-Ni-B-P types, and reference iron Fe-B-type boride layer. It was demonstrated that the new variant of hybrid treatment produces Fe-Ni-B layers with the highest thickness, slight porosity, the optimal structure of Ni2B boride in the near-surface zone and the best performance properties. These layers show good adhesion, a much higher hardness of 2200 HV0.05 and near-surface compressive stresses of −450 MPa. Fe-Ni-B-P layers show slightly better wear resistance for higher loads, but like Fe-B layers, they are susceptible to spalling. It was demonstrated that Fe-Ni-B layers produced using boriding with nickel galvanic steel precoating could find application in heavy-duty elements of nanobainitic steel processing.

3D active fault kinematic behaviour reveals rapidly alternating near-surface stress states in the Eastern Alps

Abstract Stress variations in the Earth's crust need to be understood in both the spatial and temporal domains to address a number of pressing societal issues. In this paper, precise three-dimensional records of fault kinematic behaviour obtained by mechanical extensometers are used to investigate changes in stress states along major faults in the Eastern Alps. The monitored faults are fractures with evident Upper Quaternary displacement and are directly attributed to their master tectonic structures. The results demonstrate that activity at the submillimetric scale is highly episodic; periods of repose are punctuated by conspicuous reactivation events affecting one or more of the displacement components. An original approach named the SMB2018 method is used to define the stress state associated with each fault reactivation event. The outputs evidence significant short-term changes in the local stress regime. The directions of the principal normal stresses calculated from these reactivation events present generally similar patterns for both compressional and extensional stress states. Consequently, submillimetric fault activity cannot be controlled by a rotating stress field; such shifts can only be caused by a change in the magnitude of the individual principal normal stresses so that the maximum compression changes to the minimum and vice versa.

Establishment and experimental verification of a three-dimensional finite element model for residual stress in surface processing of Inconel 718 alloy by laser cladding

The local load and residual stress changes of conventional forged Inconel 718 alloy can be simulated in a two-dimensional (2D) cutting simulation model, but the type and distribution of global residual stress field of the alloy cannot be predicted during laser cladding layer cutting. To address the shortcomings of conventional 2D cutting simulation models for forging Inconel 718 alloy, this paper proposed a 3D closed-loop finite element model, and taking the dry-side milling process of Inconel 718 alloy laser cladding layer as an example, the generation mechanism and distribution of residual stress are predicted during the machining process. Further testing of surface, near-surface, and subsurface residual stresses was conducted to analyze the specific distribution of residual stresses in the workpiece. The results indicated that the uneven distribution of cutting stress and temperature on the workpiece had a significant non-stationary thermal-mechanical effect on the surface of the machined workpiece; the distribution of surface residual stress was uneven, with the significant tensile residual stress at the workpiece boundary. As the depth increases, the influence of mechanical effects dominated, and the compressive residual stress was generated on the subsurface of the workpiece. Residual stress testing was conducted on the surface/near-surface, and the experimental results were consistent with the simulation results of the closed-loop simulation model. In the subsurface, residual stress showed a similar trend of change. This study compensated for the shortcomings of conventional finite element simulation and provided the reference value for the application of three-dimensional finite element simulation in laser cladding materials.

Atmospheric Dynamic Response to Coupling Currents to Wind Stress over the Gulf Stream

Atmospheric near-surface stress and boundary layer wind responses to surface currents are examined with high resolution coupled atmosphere–ocean models over the Gulf Stream during winter. Because the ocean and atmosphere are linked through surface stress, the two fluids can cause dramatic changes through feedback processes. When the current feedback is included, we find that the current gradient in the cross-wind direction drives the stress curl pattern and wind curl pattern to have minima and maxima at locations matching those of the ocean surface vorticity pattern. Furthermore, we find the large- (&gt;30 km) and small-scale, or submesoscale (&lt;30 km), stress curl and wind curl responses to ocean surface vorticity are complimentary; however, the large- and small-scale wind divergence responses are counteractive. These responses (commonly called coupling coefficients) are found to depend on the relative position to the Gulf Stream maximum current. Throughout the atmospheric boundary layer, we find including the current feedback also leads to changes in the atmospheric secondary circulation on either side of the Gulf Stream extension. The winter seasonal means suggest the current feedback will impact climate, and investigating individual events, such as an atmospheric front passing over the Gulf Stream, suggests the current feedback will also impact the intensity of weather.

Mechanical and Surface Geometric Properties of Reinforcing Bars and Their Significance for the Development of Near-Surface Notch Stresses

Due to the production process, reinforcing steel bars possess an inhomogeneous microstructure associated with different material properties over the cross-section (e.g., hardness, ductility or strength). Furthermore, the surface required for the bond has a negative effect on the fatigue behavior. The first investigations were carried out in the 1970s and detected the fillet radius r as a key influencing factor. Until now, few studies had been carried out that investigate the quantification of the surface properties on the fatigue behavior, and none of them compared these properties with the local strengths of the material. The current paper presents the first results of a reverse-engineered reinforcing steel bar based on a previously performed laser scanning process. The rebar models were used to calculate the notch stress factors for different diameters based on von Mises stresses taken from FEM simulations. The notch stress factors showed a functional relationship with the fillet radius, which was already shown in the literature. Further experimental investigations on the fatigue and tensile behavior of the structural components in the investigated Tempcore® rebars were carried out on microstructure specimens eroded by WEDM. The results of the tensile tests were used to derive a yield and tensile strength distribution in the cross-section. Depending on the microstructure, a yield strength between 415 N/mm2 (ferrite/pearlite core) and 690 N/mm2 (tempered martensite surface) was found. The acting notch stresses show a logarithmic dependency of the fillet radius, but do not reach the material strength of the surface.

Energy-dispersive X-ray stress analysis under geometric constraints: exploiting the material's inherent anisotropy.

Two data evaluation concepts for X-ray stress analysis based on energy-dispersive diffraction on polycrystalline materials with cubic crystal structure, almost random crystallographic texture and strong single-crystal elastic anisotropy are subjected to comparative assessment. The aim is the study of the residual stress state in hard-to-reach measurement points, for which the sin2ψ method is not applicable due to beam shadowing at larger sample tilting. This makes the approaches attractive for stress analysis in engineering parts with complex shapes, for example. Both approaches are based on the assumption of a biaxial stress state within the irradiated sample volume. They exploit in different ways the elastic anisotropy of individual crystallites acting at the microscopic scale and the anisotropy imposed on the material by the near-surface stress state at the macroscopic scale. They therefore complement each other, in terms of both their preconditions and their results. The first approach is based on the evaluation of strain differences, which makes it less sensitive to variations in the strain-free lattice parameter a 0. Since it assumes a homogeneous stress state within the irradiated sample volume, it provides an average value of the in-plane stresses. The second approach exploits the sensitivity of the lattice strain to changes in a 0. Consequently, it assumes a homogeneous chemical composition but provides a stress profile within the information depth. Experimental examples from different fields in materials science, namely shot peening of austenitic steel and in situ stress analysis during welding, are presented to demonstrate the suitability of the proposed methods.

Analysis of Thermally Induced Strain Effects on a Jointed Rock Mass through Microseismic Monitoring at the Acuto Field Laboratory (Italy)

The study of the deformation of rock masses in response to near-surface thermal stresses is nowadays considered crucial in the field of geological risk mitigation. The superposition of heating and cooling cycles can influence the mechanical behavior of rock masses by inducing inelastic deformations that can trigger shallow slope instabilities, such as rockfalls and rock topples. This study reports the main outcomes obtained from the analysis of 20 month long microseismic monitoring at the Acuto field laboratory (Central Italy), where an integrated geotechnical and geophysical monitoring system has been operating since 2015. A preliminary event classification was performed through the analysis of time- and frequency-domain characteristic features of the extracted waveforms. Furthermore, the evolution of the local microseismicity was explored as a function of environmental factors (i.e., rock and air temperature, thermal gradients and ranges, and rainfalls) to highlight potential correlations. The here presented results highlight nontrivial insights into the role played by continuous near-surface temperature fluctuations and extreme thermal transients in influencing the stability of rock masses. In particular, the comparison of monitoring periods characterized by the most intense microseismic activity highlights a peculiar distribution of microseismicity during the heating and cooling phases of the rock mass in relation to different environmental conditions. These behaviors can be interpreted as the consequence of different driving mechanisms at the base of local failures.

Alloy modification for additive manufactured Ni alloy components Part II: Effect on subsequent machining properties

Alloy 36 (1.3912) is an alloy with 36% nickel and 64% iron and is generally classified as a difficult-to-cut material. Increasingly complex structures and the optimization of resource efficiency are making additive manufacturing (AM) more and more attractive for the manufacture or repair of components. Subsequent machining of AM components is unavoidable for its final contour. By using modern, hybrid machining processes, e.g., ultrasonic-assisted milling (US), it is possible to improve the cutting situation regarding the resulting surface integrity as well as the cutting force. Part I deals with the influence of the alloying elements Ti, Zr, and Hf on the microstructure and the hardness of the initial alloy 36. Part II focusses on the effect of the alloy modifications and the ultrasonic assistance on machinability as well as on the surface integrity after finish-milling. The results show a highly significant influence of the ultrasonic assistance. The cutting force during the US is reduced by over 50% and the roughness of approx. 50% compared to conventional milling (CM) for all materials investigated. Moreover, the US causes a defect-free surface and induces near-surface compressive residual stresses. CM leads to a near-surface stress state of approx. 0 MPa.

The sensitivity of the Eocene–Oligocene Southern Ocean to the strength and position of wind stress

Abstract. The early Cenozoic opening of the Tasmanian Gateway (TG) and Drake Passage (DP), alongside the synergistic action of the westerly winds, led to a Southern Ocean transition from large, subpolar gyres to the onset of the Antarctic Circumpolar Current (ACC). However, the impact of the changing latitudinal position and strength of the wind stress in altering the early Southern Ocean circulation has been poorly addressed. Here, we use an eddy-permitting ocean model (0.25∘) with realistic late Eocene paleo-bathymetry to investigate the sensitivity of the Southern Ocean to paleo-latitudinal migrations (relative to the gateways) and strengthening of the wind stress. We find that southward wind stress shifts of 5 or 10∘, with a shallow TG (300 m), lead to dominance of subtropical waters in the high latitudes and further warming of the Antarctic coast (increase by 2 ∘C). Southward migrations of wind stress with a deep TG (1500 m) cause the shrinking of the subpolar gyres and cooling of the surface waters in the Southern Ocean (decrease by 3–4 ∘C). With a 1500 m deep TG and maximum westerly winds aligning with both the TG and DP, we observe a proto-ACC with a transport of ∼47.9 Sv. This impedes the meridional transport of warm subtropical waters to the Antarctic coast, thus laying a foundation for thermal isolation of the Antarctic. Intriguingly, proto-ACC flow through the TG is much more sensitive to strengthened wind stress compared to the DP. We suggest that topographic form stress can balance surface wind stress at depth to support the proto-ACC while the sensitivity of the transport is likely associated with the momentum budget between wind stress and near-surface topographic form stress driven by the subtropical gyres. In summary, this study proposes that the cooling of Eocene Southern Ocean is a consequence of a combination of gateway deepening and the alignment of maximum wind stress with both gateways.

Topographic response to ocean heat flux anomaly on the icy moons of Jupiter and Saturn

Recent studies of ocean dynamics suggest that the long-wavelength topography of some icy moons may reflect the phase transitions (melting/freezing) at the interface between the ice shell and the water ocean. Despite the obvious importance of phase changes in the evolution of icy moons, very little is known about how these processes influence their shape, gravity and near-surface stress. Here we address this issue by performing a series of numerical experiments in which we explore the thermo-mechanical response of an ice layer to heat flux variations imposed at the bottom (phase) boundary. We assume that the heat flux from the ocean consists of two components: the heat flux originating in the deep ocean and associated with the global ocean circulation, and the heat flux due to the flow of water generated by variations in the melting temperature along the deformed ice–water interface. The effect of salinity on the heat flux from the ocean is neglected. We demonstrate that the mass exchange between the ocean and the ice layer is a natural consequence of the ice–water phase transition and it occurs in both convection and conduction modes, regardless of whether the system is in equilibrium or not. The magnitude of the heat-flux induced topography strongly depends on the viscosity of ice and the flow of water controlled by the melting temperature. When heat transfer in the ice shell occurs by convection, the surface topography is dominated by small-scale convective features varying in time and its large-scale component does not exceed 10 m. When the viscosity of the ice shell is high (≳1016 Pas) and the heat is transferred by conduction, the topography is negatively correlated with the heat flux from the ocean and its amplitude increases with increasing viscosity. Topographic amplitudes comparable to those observed on Titan, Enceladus and Dione are obtained only if the water flow associated with lateral variations in the melting temperature is neglected. This suggests that this flow may be too weak to reduce the variations in ice shell thickness and the motion of water along the phase boundary is more likely to be controlled by other factors, such as variations in salinity and the presence of non-ice material. In addition, we show that the standard formulation of Airy isostasy can lead to an error of 5%–15% in determining the variations in ice thickness and we propose a new formulation that takes into account the effect of thermal expansion.

Effects of Local Vegetation and Regional Controls in Near-Surface Air Temperature for Southeastern Brazil

The spatial range of near-surface air temperature average and trends for Southeast Brazil in recent decades motivated us to investigate the causality of local vegetation and other geophysical controls at the regional scale to explain the spatial variability of the average maximum and minimum temperature (Tmax and Tmin). We used measurements from 52 weather stations between 1985 and 2010. Using linear regression, NDVI and cloud cover were significant to explain spatial variability of Tmax and Tmin. With the Generalized Additive Model (GAM), we improved temperature-dependent relationships with regional geophysical controls, and local scale NDVI. The modeling of Tmax and Tmin showed non-linear and combined relationships with geographical position (lat,lon) jointly expressing the effects of zonality and continentality, and NDVI at distances of 300 m and 3000 m. For Tmin, geographical position and altitude responded with an amplitude of ≃5 °C each, and NDVI with ≃3 °C. Similarly, the geographical position and altitude were significant for Tmax, with an amplitude of ≃5 °C each, and cloud cover with ≃3.5 °C. Our findings help to clarify the local scale controls of near-surface air temperature and stress the need to increase resilience against adversities of global climate change and increasing urbanization, by providing metrics to predict the effects of nature-based solutions within the urban space.

Nonsingular Stress Distribution of Edge Dislocations near Zero-Traction Boundary.

Among many types of defects present in crystalline materials, dislocations are the most influential in determining the deformation process and various physical properties of the materials. However, the mathematical description of the elastic field generated around dislocations is challenging because of various theoretical difficulties, such as physically irrelevant singularities near the dislocation-core and nontrivial modulation in the spatial distribution near the material interface. As a theoretical solution to this problem, in the present study, we develop an explicit formulation for the nonsingular stress field generated by an edge dislocation near the zero-traction surface of an elastic medium. The obtained stress field is free from nonphysical divergence near the dislocation-core, as compared to classical solutions. Because of the nonsingular property, our results allow the accurate estimation of the effect of the zero-traction surface on the near-surface stress distribution, as well as its dependence on the orientation of the Burgers vector. Finally, the degree of surface-induced modulation in the stress field is evaluated using the concept of the -norm for function spaces and the comparison with the stress field in an infinitely large system without any surface.

Computationally Efficient Modeling of Lightweight Expeditionary Airfield Surfacing Systems at Large Length Scales

Expeditionary airfield matting systems are lightweight, portable surfaces that enable the rapid deployment of infrastructure to support aircraft operations. Individual matting components are assembled via interlocking joints to construct arrays that serve as temporary aircraft operating surfaces. The paper outlines the homogenization of the AM2 portable airfield matting system and its interlocking mechanisms to permit computationally efficient analyses toward understanding mechanisms that influence the global behavior of these arrays and underlying subgrade during aircraft maneuvers. An equivalent orthotropic two-dimensional continuum was developed from finite element analysis of a detailed three-dimensional model and its flexural behavior was validated against experimental data and solid finite element models. Interlocking joints were characterized using node-to-node connector elements based on subscale finite element studies. Both components were implemented into a full-scale model representative of a typical test section, and responses to static high tire pressure aircraft loads were analyzed over a soil foundation representing a California bearing ratio of 6%, yielding promising agreement with experimental data. Results of this study reveal an inherent coupling between load transfer, mat deflection, and near-surface subgrade stress with dependence on tire location, mat core shear flexibility, and joint stiffness.

Evaluation of laser shock peening process parameters incorporating Almen strip deflections

Engineering of component surfaces using Laser Shock Peening (LSP) requires optimisation of key process parameters to enhance performance through the generation of beneficial compressive residual stresses. Quantification of residual stress fields typically requires considerable experimental resources involving multiple complementary techniques to obtain reliable measurements through the depth of the target material. LSP induced plastic strains lead to the formation of residual stresses and cause deformation of thin components. This effect is routinely used in the assessment of mechanical Shot Peening (SP) where distortion coupons, called Almen strips, correlate the peening intensity to process parameters. This study explores the extension of this Almen strip concept to facilitate the quick assessment of LSP parameters for aluminium alloy 6056-T4 aeronautical structural applications. Direct measurements of the resulting LSP residual stresses have been performed using Synchrotron X-Ray Diffraction, Neutron Diffraction, and Incremental Hole Drilling, complemented by analyses of surface integrity and sub-surface modifications. It has been found that the attained near-surface compressive residual stress values and depths are strongly dependent on laser power intensity and spot coverage, whilst surface roughness and microhardness are mostly independent of the LSP parameters. Optimal parameter selection should therefore be primarily focused on the required residual stress field. A direct correlation has been observed between the magnitudes of LSP Almen distortions and the residual stresses. This qualifies extending the deflection based approach to be used as a quick, simple and effective qualitative screening technique of LSP process parameters, such as the laser power intensity saturation.