Short Course Announcement – Residual Stress 101

The upcoming SEM Annual Conference and Exposition on Experimental and Applied Mechanics will include a Pre-conference Course titled: Residual Stress 101. The residual stress short course is scheduled for Sunday, June 12, 2022, from 9:00 a.m. to 5:00 p.m.

The course aims to cover a broad, practical introduction to residual stresses for students, researchers and industrialists with an interest in the subject. The course will be taught by Michael Prime, Michael Hill, Adrian DeWald, Luliana Cernatescu, Jeff Bunn, and Gary Schajer. Registration is currently open through the SEM Website.

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New Rapid Forge Design Article in FIA Magazine

Our Rapid Forge Design (RFD) software has generated a substantial amount of buzz since it’s release last year. If you’ve been keeping up with our social media accounts, you’ve probably caught us highlighting its key features and ease of use, especially through our demonstration video in which creator John Watton goes step-by-step through the closed-die impression forging design process.

For those who want a more comprehensive rundown of the software’s features and abilities, as well as plans for future design modules, John recently published an article in Forging Industry Association magazine, where he gives a history of how RFD came to be, and how it serves forgers and forging consumers.

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ASIP 2021 Presentation: Development of a Residual Stress Standard

At the recent United States Air Force Structural Integrity Program Conference (ASIP) in Austin, TX, Hill Engineering co-authored a presentation titled Development of a Residual Stress Standard. The Aircraft Structural Integrity Program (ASIP) Conference is specifically designed to bring together the world leaders in the area of aircraft structural integrity and to disseminate information on state-of-the-art technologies for aircraft structures in both the military and civilian fleets. Below is the abstract from the presentation along with a link to the full conference slides.

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HE Vlog: Introducing the Integrated Maintenance System, IMx+

In our latest vlog, Hill Engineering team member Bob Pilarczyk introduces the Integrated Maintenance System, or IMx+. This revolutionary system uses next generation technologies to address the quality assurance needs of the aerospace industry. Watch the video below for more information.

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New Publication – Measurement Layout for Stress Mapping Using Slitting

Hill Engineering recently published new research detailing our efforts to optimize the experimental technique for our PSR Biaxial mapping process, which generates a 2D map of residual stress. The paper is titled Measurement Layout for Residual Stress Mapping Using Slitting and appears in Experimental Mechanics. The abstract text is available here along with a link to the publication.

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In the Field with Ryan: On-site Residual Stress Measurements

While we at Hill Engineering take pride in our ability to perform high quality residual stress measurements in our laboratory, we recognize that not all parts and projects can be easily transported.

That’s where we bring the measurements to you with our Residual Stress Field Team. Our laboratory engineers are capable of performing residual stress measurements across the globe, and have done so on many occasions.

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Deep-Hole Drilling on a bent-beam specimen

In 2019 Hill Engineering licensed VEQTER Ltd.’s world-leading Deep-Hole Drilling (DHD) technology. Under this agreement, Hill Engineering is delivering state-of-the-art DHD measurements within the North and South American Continents. Results from a recent DHD measurement on a bent-beam specimen are shared in this blog post.

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Introducing the DART – HE Vlog

Our latest vlog highlights the DART™, our turn-key, industry-leading tool for precise, reliable, and efficient near-surface residual stress measurements. The Device for Automated Residual stress Testing is capable of multiple measurement techniques including hole drilling and TrueSlot®. This flexibility allows for easy adaption as new applications arise.

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Case Study: DART – automated residual stress measurement

Our latest case study highlights the many benefits of the DART™ automated measurement system, a tool we at Hill Engineering developed specifically to improve near-surface residual stress measurement techniques such as hole drilling and TRUEslot®.

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DART – automated residual stress measurement

Near-surface residual stress data is critical when assessing material performance, optimizing design, validating models, evaluating field failures, and executing quality assurance programs. Hill Engineering’s DART™ is an industry-leading tool for efficient, precise, and reliable near-surface residual stress measurements. The DART™ overcomes limitations of existing residual stress measurement equipment and includes everything required to perform state-of-the-art measurements in accordance with industry specifications.

Hill Engineering’s DART™

A single DART™ can perform near-surface residual stress measurements using multiple techniques including hole drilling
and TRUEslot® methods. This flexibility is helpful when requirements change or new applications arise. The DART™ executes hole-drilling residual stress profile measurements in accordance with ASTM E837, providing a depth profile of the three in-plane residual stress components in a single measurement. TRUEslot® is a novel technique, like hole-drilling, but simpler and more precise. TRUEslot® provides a depth profile of one stress component per measurement.

Hole drilling measurement example

Hole drilling results example

Residual stress measurements with the DART™ are easy to complete. A user interface guides you through set-up, then takes over for automated measurement execution and residual stress calculation.

With measurements completing in less than 60 minutes, the DART™ excels in the production quality management environment. Automated data capture, processing, and archiving provide you with residual stress results instantly.

Featuring advanced cutting strategies and real-time quality checks, the DART™ gives you confidence in your residual stress data.

• Hole drilling residual stress measurements according to ASTM E837
• TRUEslot® residual stress measurements
• Positional accuracy: ± 0.001 in.
• Works on most materials including: aluminum, titanium, steel, stainless steel, and nickel alloys
• Custom fixtures can be integrated to meet the needs of individual applications
• NFPA 79 compliant


Each DART™ includes a complete software package that enables efficient and repeatable residual stress measurements for high-volume or single-use applications. DART™ software is designed for ease-of-use, while maintaining flexibility to meet your measurement needs and providing controls to maximize reliability. An operator defines the measurement location, the type of measurement (TRUEslot® or hole-drilling), and inputs the key measurement details. Following set-up, the software automatically controls the incremental material removal process, acquires the experimental data, computes residual stress, and outputs a test report. The entire process is significantly more efficient than other available tools.

DART™ produces the highest-quality residual stress data available
Precise engineering and extensive use of automation within the DART™ provides a demonstrated 50%+ improvement in measurement repeatability relative to other hole drilling test equipment. Hole drilling and TRUEslot® measurements performed using a DART™ have been shown to be 60%+ more repeatable than X-ray diffraction measurements.

DART™ outperforms its competitors in RS measurement repeatability

The DART™ has proven to meet our high internal standards for data quality and is currently in use in multiple facilities throughout the world. It could be in your facility soon.

To place an order for DART™ related goods or services, please contact us.

Download a DART™ brochure here

DART™ and TRUEslot® are protected by US Patent 10,900,768 and are patent pending for other international jurisdictions.