Residual stresses are inherent stresses that exist in engineering components even though no external load is applied. They are caused by the non-uniform volumetric shift of the metallic component during manufacturing processes. Welding is a key manufacturing technique that has a substantial impact on the economy since it is required for the production of a diverse variety of products used in the engineering sector. The residual stress primarily affects the stability, durability and performance of the welded joints. Hence its determination is of utmost importance. X-ray diffraction (XRD) is the most commonly used method for residual stress analysis. There are mainly two approaches for measuring residual stress using XRD; one is the sin²ψ method and the other is the cosα method. The residual stress measurements using the cosα method are handy, quick and convenient compared to the sin²ψ method. This method is well suited for welded joints, as it provides flexibility for testing immediately after the welding operation. Apart from residual stress measurements, the cosα method also gives valuable insights in the form of Debye-Scherrer (DS) rings and full width at half maximum. The present study focuses on the development of a novel technique that not only enables residual stress measurement but also provides a quantitative estimation of hardness and qualitative estimation of grain size without performing metallurgical or mechanical characterization. The material used for the present study is an arc-welded joint of MDN 250 grade maraging steel. The residual stress results show a compressive profile throughout the weldment, with a maximum value of compressive residual stress of 428 MPa at the fusion zone.

残余应力是工程部件中存在的固有应力，即使没有施加外部载​​荷。它们是由制造过程中金属部件的非均匀体积位移引起的。焊接是一种关键的制造技术，对经济产生重大影响，因为它是生产工程部门使用的各种产品所必需的。残余应力主要影响焊接接头的稳定性、耐久性和性能。因此，它的确定至关重要。X 射线衍射 (XRD) 是最常用的残余应力分析方法。使用XRD测量残余应力主要有两种方法；一是罪²ψ法，另一种是cosα法。与 sin ²相比，使用 cosα 方法测量残余应力更加方便、快速和方便ψ法。这种方法非常适合焊接接头，因为它为焊接操作后立即测试提供了灵活性。除了残余应力测量外，cosα 方法还以 Debye-Scherrer (DS) 环和半峰全宽的形式提供有价值的见解。本研究的重点是开发一种新技术，该技术不仅可以测量残余应力，还可以提供硬度的定量估计和晶粒尺寸的定性估计，而无需进行冶金或机械表征。本研究使用的材料是 MDN 250 级马氏体时效钢的弧焊接头。残余应力结果显示整个焊件呈压缩分布，熔合区的残余压缩应力最大值为 428 MPa。