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.

Continue reading New Publication – Measurement Layout for Stress Mapping Using Slitting

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.

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

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.

Continue reading Deep-Hole Drilling on a bent-beam specimen

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.

Continue reading Introducing the DART – HE Vlog

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®.

Continue reading Case Study: DART – automated residual stress measurement

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.

Hill Engineering awarded patent for innovative DART system

Hill Engineering was recently awarded US Patent 10,900,768 for residual stress measurement technology. Granted on January 26, 2021, the title of the patent is “Systems and Methods for Analysis of Material Properties of Components and Structures Using Machining Processes to Enable Stress Relief in the Material Under Test..” The patent abstract is available below. There is a link at the end to download and read it in full.

Continue reading Hill Engineering awarded patent for innovative DART system

Rapid Forge Design brochure

Hill Engineering’s Rapid Forge Design is an automated tool for the fast and reliable design of 2-piece, closed-die impression forgings. The brochure below provides a rundown of the highlights from this powerful software, which can drastically reduce the time needed to design a forging to industry-accepted standards.

Continue reading Rapid Forge Design brochure