The residual stress analysis is a well-established method for predicting fatigue failures of mechanical components. Within industrial constraints, the X-ray diffraction is a technique usually applied to measuring a small spot of the workpiece surface. This punctual and averaged outcome does not allow the proper representation of the residual stress. The objective of this study is to define a feasible method for assessing the heterogeneity of the surface residual stress state. The proposal is based on the theoretical relationship between the deviation of the residual macrostress and the intensity of the microstress. Steel shot peened gears were produced and their microstresses were assessed by means of the diffraction profiles broadening. The reference database was composed of topography measurements, metallographic analyses and residual macrostress maps. The stress heterogeneity was reasonably correlated to the intensity of the Gauss integral breadth. Applied to ground parts, the correlation’s parameter filled a comprehension gap between the measured residual stress intensity and observed contact fatigue failures. Using the same data from the macro residual stress measurement, the method proved to be feasibly applied. Moreover, by providing a deviation perspective to the residual stress state, the heterogeneity assessment enhances the analysis of a fatigue failure.
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