Cold Gas Spraying (CGS) is a solid-state thermal spray process in which powder particles are accelerated to supersonic velocities by a high-pressure gas and deposited onto a substrate without melting. The bonding mechanism relies on the confined plastic deformation of the particles, known as adiabatic shear instability, promoting oxide removal and mechanical interlocking. CGS typically induces compressive residual stresses (RS) near the surface due to the dominant peening effect, contrasting with tensile RS often observed in conventional thermal spray processes [1-3]. This work investigates the application of CGS for repairing components made from Inconel 718, focusing on how cavity geometry and repair location influence local RS distribution, which is critical for structural integrity and resistance to delamination. While neutron diffraction enables non-destructive, high-resolution RS characterization, its use is limited by accessibility, the need for large-scale facilities, and the high neutron absorption of nickel-based alloys. Additionally, plastically deformed materials exhibit broad diffraction peaks, complicating analysis. To address these limitations, the contour method [4] is evaluated as an alternative. Although destructive, it offers full cross-sectional RS mapping on a laboratory scale, making it a promising option for repair assessment. Flat Inconel 718 samples with tapered cavities (4 mm depth) were manufactured and repaired using CGS. The tapered design facilitates gas flow and improves adhesion during spraying. In addition to contour measurements, RS were characterized using neutron diffraction at the SALSA@ILL instrument [5], complemented by incremental hole drilling for near-surface validation. Figure 1 is showing a comparison of the expected RS distribution, based on the results from neutron diffraction experiments (Figure 1a) with the RS distribution obtained from the contour method. These datasets provide a benchmark for assessing the contour method’s capability to capture steep RS gradients at the repair-substrate interface. The scientific question addressed is whether the contour method can reliably resolve local RS distributions in CGS-repaired regions, where strong gradients occur between the deposit and substrate. Comparing results from destructive and non-destructive techniques will clarify the method’s suitability for analysing the RS distribution throughout CGS repairs of Inconel 718 components. Ultimately, this research aims to establish robust RS characterization strategies for CGS repairs, supporting their implementation in critical applications where mechanical integrity and fatigue performance are paramount.