This article presents a research approach that enables the assessment of the technical condition of complex technical objects. The main emphasis is placed on the load-carrying structures of these objects. The procedure applying experimental research techniques and computer computations using the finite element method is described. The combination of the two techniques assesses the technical condition of the structure. The described approach is presented using the example of two objects.

Thermoelastic Stress Analysis (TSA) is one of the very few methods allowing the determination of a continuous stress distribution on the object’s surface under variable loading conditions. Such results provide a lot of valuable information in the field of technical condition assessment and residual life prediction. In order to improve the accuracy of the TSA, the Lock-In signal processing method is implemented. This research is aimed at verifying the effectiveness of this improvement and determining the TSA stress detection threshold, as it is important information in terms of the applicability of this method in the low-stress conditions encountered in considerations of fatigue of load-carrying structures. A steel sample with a centrally located hole was subjected to cyclic loads to determine the threshold of stress detection and accuracy of TSA. As a result of the research, the relationship between the magnitude of stress excitations and the underestimation of the measured stresses was developed. Based on the conducted investigations, it was concluded that reasonable TSA results can be acquired for excitations that induce a temperature response above 10 mK (0.5 NEDT). The presented field test example proves that in industrial applications reasonable results can be acquired for thermal responses below the NEDT of the IR camera. It was concluded that it is possible to successfully implement TSA in low-stress applications (temperature response below NEDT).