Aircraft structural components are complex and expensive due to their manufacturing process complexities and use of high-performance materials. Aerospace components are susceptible to in-service damages, such as wear, dents, corrosion pits, and cracks; caused by corrosion, fatigue loads, foreign object damages, etc. In most cases, repair or re-manufacturing is a more feasible and economical solution than replacement. Re-manufacturing of aerospace components may deliver significant financial savings between 30-70% of the cost of replacement. However re-manufacturing process namely cold spray, in this case, induces significant residual stresses that has implications on the structural integrity of the part. This proposal aims to characterise these stresses as a function of the spraying process in order to better understand its effect on the structural intergrity and damage resistance.