Distortion Engineering

Hill Engineering’s expertise in residual stress technologies make us a valuable resource in addressing distortion challenges that can arise during machining of materials. The most straightforward approach to managing machining distortion is to ensure the incoming material stream has consistent, and small residual stress fields. In some conditions, it is necessary to manage machining of material containing moderate levels of residual stress. When machining is not properly planned, residual stress in the initial material form can cause cracking or unexpected shape change during material removal.

Our team provides residual stress engineering services to help you procure in-bound materials with low residual stress, and a quality control program that monitors your material stream for consistent residual stress over time.

We also have extensive experience in the use of residual stress processing technologies, like coining, shot peening, and laser shock peening, that can be applied to reshape parts that are out of tolerance. The ERS-toolbox® is highly effective in engineering of part reshaping.

Further information on residual stress engineering
Fatigue Life Extension
Quality Control
Distortion Engineering
ERS-Toolbox®



Illustration of part distortion due to bulk residual stress in a machined aerospace component.

Photograph of a distorted machined aerospace component.