Draw a square on an elastomer strip and stretch it:
"OK, I get this:"
The lengthwise load (comprising two force vectors, to the left and to the right) applies a stress state on the shape. What kind of stress?
"I'll assume the stress state can be expressed as a vector. I guess the vector corresponds to normal stresses to the left and to the right (i.e., forces acting perpendicular to the left and right sides). This is consistent with normal stresses changing side lengths of infinitesimal elements. I guess I'll call the vector [1 0 0], where I've normalized by the load magnitude."
Now consider drawing not a square but a diamond, for the same load.
"OK, now I get this:"
What is the stress state?
"It now includes some shear stress, since interior angles are now changing. Effectively, some forces on the sides are now parallel instead of solely perpendicular. The vector [1 0 0] doesn't capture this change, nor can I transform it rotationally to scale with [1 1 0] or [1 -1 0], say, because the diamond doesn't deform that way either; it stretches more to the left and right than it shrinks up and down. Hmm.
"Nature doesn't care which way we draw our coordinate systems, so we need a mathematical representation that transforms correctly. I have to conclude that a vector is incapable of representing the stress. However, a tensor would work:
$$\left[\begin{array}{ccc} 1 &0 &0\\0& 0& 0\\0& 0 &0\end{array}\right]$$
would transform upon a 45° rotation into
$$\left[\begin{array}{ccc} 1/2 &1/2 &0\\1/2& 1/2& 0\\0& 0 &0\end{array}\right],$$
which is consistent with the observed deformation of the diamond. Specifically, the side lengths stretch equally from an equibiaxial stress—from the diagonal elements—of 1/2, and this is superimposed on a shape change from a shear stress—from the off-diagonal elements—of 1/2.
"Furthermore, the tensor satisfies the standard requirements, such as invariance of the trace (here, 1) and two other invariants. These invariants capture the true essence of the stress state, which must be coordinate independent."
Why not just list those indices as, say, [½ ½ 0 ½ ½ 0 0 0 0] to make a vector?
"That not a true Cartesian vector, which has three elements and a well-defined direction. It's just a list."
One more question. When we apply a load on a surface, the resulting stress state has a well-defined direction that corresponds to the load. Why isn't a tensor needed here?
"A tensor is still needed to describe the stress state because of the above reasoning, but neither the surface nor the load are free to rotate, so any infinitesimal element aligned with the surface is constrained. Although this appears to suggest that stress has a single direction, its a particular result of the constraint and doesn't hold in general."
(Images from my site, adapted from a photograph by Nelson Fitness.)