Measuring multiple residual-stress components using the contour method and multiple cuts Page: 4 of 17
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Pagliaro et al. 2/16
Introduction
The recently introduced contour method provides uncommon capabilities for residual
stress measurement [1], most notably the ability to make a two-dimensional (2D) cross-sectional
map of residual stresses. In the contour method, the part is cut into two and the measured contour
of the exposed surface is used to calculate stresses. The contour method is useful for studying
various manufacturing processes such as laser peening [2-5], friction stir welding [3,4,6] and
fusion welding [1,7-10]. Some of the applications are quite unique such as mapping stresses in a
railroad rail [11], in the region of a individual laser peening pulse [12], and under an impact
crater [13].
Advantages of the contour method are accompanied by the limitation that the
conventional contour method can only measure the stress component normal to the cut plane.
However, it is difficult to measure a 2D map of multiple residual-stress components with other
techniques. Sectioning techniques, which require multiple cuts and strain gauges, can in principle
reconstruct a three-dimensional (3D) stress map [14,15]. These techniques are time consuming
and rarely applied. Spatially refined 2D or 3D neutron diffraction stress maps [16] have practical
limits because the required beam time grows exponentially with the dimensionality of mapping.
The deep hole method can measure multiple stress components through the thickness of a part
but only provides a 1 D stress profile [17]. An alternate approach for full-field residual stress
determination is to use analytical techniques with physically based assumptions, such as
eigenstrain, to expand limited measurements to a more complete stress state [5,15,18-23].
There are several approaches, each with unique capabilities, for augmenting the
conventional contour method to measure multiple stress components. The method presented in
this paper uses multiple cuts and reconstructs the original residual stress component normal to
each cut. Original residual stresses are those before the first cut rather than after the first cut has
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Prime, Michael B; Swenson, Hunter; Pagliaro, Pierluigi & Zuccarello, Bernardo. Measuring multiple residual-stress components using the contour method and multiple cuts, article, January 1, 2009; [New Mexico]. (https://digital.library.unt.edu/ark:/67531/metadc925879/m1/4/: accessed April 24, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.