Heat Treatment, Furnaces & Thermal Processing worked example

Stress Relief Cost at 61% cost capture rate: a worked example

Suppose cost capture rate falls to 61%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate stress relief cost from load size, per-part stress relief rate, cost capture, and fixed furnace or certification adders.

The inputs for this scenario

  • Parts in stress-relief load: 120 parts (held at the documented default)
  • Stress relief rate per part: 3.4 $/part (held at the documented default)
  • Cost capture rate: 61 % (the input this scenario stresses; the baseline uses 85)
  • Furnace and cert adder: 400 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total cost = parts in load x stress relief rate per part x cost capture% + furnace and cert adder.
  • Total stress relief cost works out to 649 $ at these inputs, and this is the headline figure for the scenario.
  • Stress relief cost per pound works out to 5.41 $ / lb at these inputs.
  • Captured stress relief cost works out to 249 $ at these inputs.
  • Fixed stress relief adder works out to 400 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where cost capture rate sits at 85% and the headline result is 747 $, this scenario comes in 13.11% below the baseline at 649 $.
  • It multiplies parts in the load by a per-part rate and a capture percentage, then adds a furnace and certification adder to give total stress relief cost and cost per part. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Total stress relief cost: 649 $ (headline result)
  • Stress relief cost per pound: 5.41 $ / lb
  • Captured stress relief cost: 249 $
  • Fixed stress relief adder: 400 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Stress Relief Cost calculator, set cost capture rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.