Residual stress (RS) management is a concept according to which three major stages, i.e. RS determination, RS fatigue analysis and RS beneficial redistribution are considered and evaluated, either experimentally or theoretically to achieve the optimum performance of welded structures. All three stages as well as a number of new engineering tools such as ultrasonic computerized complex for residual stress measurement, UltraMARS, software for analysis of the effect of residual stresses on the fatigue life of welded elements, ReSIsT, and new technology and, based on it, compact system for beneficial redistribution of residual stresses by ultrasonic impact treatment, UltraPeen, will be discussed. Examples of industrial applications of the developed engineering tools for residual stress analysis and fatigue life improvement of welded elements and structures will be given.

Residual stresses introduced before, during or after welding may change considerably the engineering properties of materials and structural components by affecting their fatigue life, distortion, dimensional stability, corrosion resistance, etc. They play an exceptionally significant role in fatigue of welded elements. The concept of residual stress management is helping the welding community to fully understand the effect of residual stresses by addressing major aspects of residual stresses in welds and welded structures. According to the concept three major stages, i.e. RS determination, RS analysis and RS redistribution are considered and evaluated, either experimentally or theoretically to achieve the optimum performance of welded structures. The welding community benefits directly from the RSM concept at all stages of the welding process. This report will provide an overview on the advancements made in addressing the development of instrumentation for providing solutions in the major stages of the RSM concept. New examples of industrial applications of the developed engineering tools for residual stress analysis and fatigue `life improvement of welded elements and structures are given.