Reduced fatigue strength: Residual stresses can act in conjunction with applied loads, reducing the service life of the material under cyclic loading conditions.
Fracture proneness: They can increase the susceptibility of the material to fracture, especially under critical loading conditions or in the presence of defects.
Distortion and deformation: Non-uniform stresses can cause components to deform or twist unexpectedly during or after processing.
Stress corrosion: Residual stresses can accelerate corrosion processes, especially in aggressive environments, leading to premature failure.
Downstream processing problems: Residual stresses can interfere with downstream processes such as machining or assembly, affecting the accuracy and quality of the final product.