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Review
. 2022;62(9):1521-1530.
doi: 10.1007/s11340-022-00879-x. Epub 2022 Aug 12.

Why Is It So Challenging to Measure Residual Stresses ?

G S Schajer  1 , M B Prime  2 , P J Withers  3
Affiliations
Review

Why Is It So Challenging to Measure Residual Stresses ?

G S Schajer et al. Exp Mech. 2022.

Abstract

Background: Residual stresses have a "hidden" character because they exist in a material without the presence of any external loads. They cannot easily be added or subtracted in a quantified manner, as is done when measuring applied stresses, and so are much more challenging to measure.

Objective: The objective here is to identify and describe the various features that make residual stress measurement methods challenging and to consider the ways that these challenges can be addressed in practice.

Methods: Various of the most common residual stress measurements methods are considered and the challenges associated with them are identified and classified.

Results: Five major challenges for residual stress measurements, and the approaches used for their resolution, are identified.

Conclusions: Despite the various challenges that need to be overcome, residual stress measurements can be successfully undertaken in practice. The most significant feature for success is a highly skilled and knowledge practitioner.

Keywords: Challenges; Measurement; Residual Stress.

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Conflict of interest statement

Conflict of Interest StatementThe authors report no conflict of interest.

Figures

Fig. 1
Fig. 1
Excision method for measuring residual stresses
Fig. 2
Fig. 2
Stress Profiling measurement methods. (a) layer removal, (b) Sachs’ method, (c) slitting, (d) hole-drilling
Fig. 3
Fig. 3
Contour Method. (a) Original stresses, (b) Stress-free after cutting, (c) Stresses to restore flat surface, (d) Measured stress profile of a worn railway rail
Fig. 4
Fig. 4
Diffraction of X-rays from near surface crystal grains oriented for diffraction from the (hkl) crystalline lattice planes
Fig. 5
Fig. 5
Schematic arrangement of a residual stress measurement by neutron diffraction
See this image and copyright information in PMC

References

    1. Noyan IC, Cohen JB. Residual Stress in Materials. Am Sci. 1991;79(2):142–153.
    1. Schajer GS (ed) (2013) Practical residual stress measurement methods. Wiley, Chichester, UK
    1. Withers PJ, Bhadeshia HKDH. Residual stress. Part 2 - Nature and origins. Mater Sci Technol. 2001;17(4):366–375. doi: 10.1179/026708301101510087. - DOI
    1. Schajer GS (2001) Residual stresses: Measurement by destructive methods. In: Buschow KHJ, et al. (eds) Encyclopedia of Materials: Science and Technology, Section 5a, Elsevier Science, Oxford
    1. Hauk V (ed) (1997) Structural and residual stress analysis by non-destructive methods. Elsevier, Dordrecht, The Netherlands

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