Residual stress evaluation and performance reliability of single crystal nickel-based alloys through a fast peak-finding algorithm

Structural health monitoring (SHM) is crucial for high-performance systems like aerospace engines, enabling early detection of damage and potential failures in key components, especially turbine blades under extreme temperatures and stress. Residual stress is a major factor in component failure, requiring precise measurement. This study proposes a fast peak-finding algorithm using local scanning, integrating Kikuchi diffraction and crystal structure features to optimize residual stress testing via X-ray diffraction. The method reduces scans from 25,631 to 792, significantly improving accuracy and efficiency. Experimental results confirm its reliability across materials under various conditions, enhancing SHM effectiveness.