Structural components are often operated under combined stress conditions (primary and secondary stresses), but the stress levels generated by residual stress (or secondary stress) is hardly ever evaluated. Hence, stress intensity factors at the crack tips of a compact tension (CT) specimen under a pre-compressed load condition are analyzed using the finite element method. Then, the average residual stress intensity factor is calculated and analyzed. As the crack length α0/W increases, the average residual stresses σave/σ0 grows under the same pre-compression load. σave/σ0 increases rapidly at a low range of the pre-compression load but tends to a constant in a high range of the load. The distribution of the average residual stress intensity factors Kave and Κave/σ0 of the CT specimen with same crack length under different pre-compression loads have the same tendency. Additionally, the distribution of Κave and KFEM under different pre-compression loads are also similar. Nevertheless, Kave estimated by the average residual stress is too conservative and not accurate, and the method is complex, which depends on the analysis of simulation. Therefore, a simple method for calculating Mode I stress intensity factor K for this model is presented. A group of examples is presented to verify the accuracy of the method.
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