The work presented in this paper explores the through-thickness distribution of residual stresses in a valve seat of complex geometry where a Tristelle insert was HIP-bonded to a Type 316 stainless steel body. The contour method was conducted in a novel way to measure a full cross-sectional map of hoop stress at an axial-radial plane along the length of the valve seat. Special care was applied to control and optimise the cutting step of the measurement technique in order to produce cut surfaces of high quality thereby minimising potential associated errors in stress. The innovation in the present work was to use sacrificial material to avoid any cutting artefacts introduced by the cutting process. High levels of residual stresses were measured in the region where an insert was HIP-bonded to the main body. The excellent correlation between the stresses measured using the contour and incremental centre hole drilling methods demonstrates the importance of controlling the quality of a contour cut and that care should be taken to avoid cutting artefacts particularly when stresses close to the surface are of interest.

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