Non-Destructive Determination of Surface Residual Stresses in Electron Beam Welded AISI 410 Martensitic Stainless Steel Using the Magnetic Barkhausen Noise Technique

Despite their excellent mechanical properties, martensitic stainless steels present significant welding challenges due to their susceptibility to cracking and forming brittle microstructures during thermal cycles. While electron beam welding offers advantages through its high energy density and precise control over conventional welding methods, the induced residual stresses remain a critical concern. This study aims to determine surface residual stresses in electron beam welded AISI 410 martensitic stainless steel using a self-developed C-scan mode Magnetic Barkhausen Noise (MBN) measurement system. A novel calibration and measurement methodology was developed to establish a quantitative relationship between MBN signals and residual stress state. The residual stresses in the welded specimens were analyzed systematically using MBN and X-ray diffraction (XRD) measurements and microstructural characterization. The results revealed a strong correlation between MBN parameters and residual stress states, showing notable variations across the weld zones, i.e., approximately +350 MPa in the heat-affected zone and −50 MPa in the base metal. The experimental findings were also validated through finite element simulations. The correlation between experimental and numerical results confirms the reliability of the proposed MBN-based methodology and system. These findings provide valuable insights for industrial applications, offering a rapid and reliable non-destructive method for residual stress assessment in critical welded components.