Review on residual stress measurement using the contour method

Contour method is a destructive residual stress measurement method based on sectioning relaxation, which can be used to obtain two-dimensional residual stress distribution normal to the cutting plane. After more than 20 years of development and improvement, the contour method is widely used in aerospace, nuclear, manufacturing and many other important industry sectors, particularly suitable for residual stress measurements of metallic welding and joint components. A comprehensive review of the contour method to clarify the technical advantages was described in detail in the paper. Theoretical foundation, measurement procedures, error correction, extended application, experimental validation and research hotspot of contour method were analyzed. Multiple cut contour method, fracture contour method, superposition measurement of X-ray diffraction method, near-surface residual stress contour method and other methods developed on the basis of single cut contour method measurement were further explored, which overcame technical limitations of traditional contour method of cross section stress and near surface stress, and 3D residual stress distribution of engineering structural parts could be obtained. It provided technical support for adjusting cutting method and measuring scheme according to different engineering application requirements, and expanded application range of contour measurement. The aim of this paper was to provide reference for domestic counterparts and help to promote application of contour method in domestic scientific research and engineering application.Highlights: (1) Compared with other traditional residual stress measurement methods, the key technical advantages and scope of applications of contour method were clarified.(2) The errors introduced during measurement were anlalysed and potential solutions were provided.(3) Applications of contour method to satisfying three-dimensional stress measurement requirements were expanded.