This study, on a micro-scale, of the WEDM cut surfaces of specimens to which the Contour Method of residual stress measurement is being applied provides detailed information about the effects of the cutting process on the surface quality. This is defined by a combination of several parameters: variation in surface contour profile, sub-surface damage and surface texture. Measurements were taken at the start, the middle and at the end of the cut. This study shows that during WEDM cutting, a thin layer, extending to a depth of a few micrometres below the surface of the cut, is transformed. This layer is known as the recast layer. Using controlled-depth etching and X-ray diffraction, it is show that this induces an additional tensile residual stress, parallel to the plane of the cut surface. The WEDM cut surface and sub-surface characteristics are also shown to vary along the length of the cut. Moreover, these micro-scale changes were compared with macro scale residual stress results and provides an indication of the point at which the changes occurred by cutting process can be significantly relative to the macro-scale residual stress in a specimen.