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The development of a deep hole method, based on earlier techniques, for measuring the through-thickness distribution of residual stresses is described. The distortion of a reference hole used in the method was interpreted using analytical techniques to determine the residual stresses present. The accuracy of the method was investigated using a 100 mm deep plastically deformed ferritic steel rectangular bar. The stresses in the bar were determined by surface strain gauges. The axial residual stresses through the depth of the bar, measured by the deep hole method, were found to be within ± 35 MPa of the stresses determined from the strain gauges in the central 80 mm of the bar.

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A new method for the measurement of residual stresses in welded joints of complex cross section is described. The method involves the measurement of strain changes in the body as a narrow slot is cut in the plane of interest, in small increments of depth. A finite element model of the cross section is used to relate the strain changes at the measurement points to the residual stresses across the slot plane. The accuracy of the method is demonstrated by using it to measure a known residual stress field in a cold bent bar. 7he method has been used in combination with u block removal technique to measure the through wall distribution of axial residual stresses at a circumferential butt weld in a cylinder with a protruding root bead. It could also be applied to the measurement of residual stresses in other joint configurations, such as fillet welds or T-butt welds.

The neutron diffraction technique for measuring residual stresses non-destructively in an aluminium alloy weld has been examined. Calibration experiments have been performed to determine the influence of prior plastic strain and surface effects. Comparisons have also been made with strain gauge methods using the destructive block removal and layering technique for measuring the residual stresses. It has been shown that the neutron diffraction method gives an accurate indication of the three dimensional stress distribution present in a weld and that it can also be employed to estimate the amount of prior plastic strain encountered.