Plug welds

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Not real happy with this fixSo, when you have some clients that send machining cell boo-boos from time to time the fix is usually simple. Not so this time... Instead of sending holes with broken taps to the their toolroom for surgery they just plunged an end mill through to the bore!In my day reject tags said "REJECT" and either rework or "SCRAP", if it was bad enough it was painted white with "SCRAP" in red letters, and then placed in clear view somewhere... The tags were the only light moment in this work.Onward, I gave them several solutions first being "SCRAP", 2nd being 1% nickel hard wire, 3rd being 2% metal core and throw the wire away when done (I'm not keeping the stuff & they have no rod oven). I asked for an ECN and approval of my WPS or substitute. Some time went by and "bang" ECN and 1%NI option comes back, ECN numbers to be stamped with my symbol underneath...SHOOT.The holes were filled in 4-6 passes depending on the depth, the castings run 240bhn so they are good but not crazy good so a 600°F limit is OK, 800 within an inch or so I'll start doing some real damage. The wire was .035 using a 90Ar/8Co2/2O2 tri-mix 500IPM and starting at 23.5 volts (I'm trying to stay just under a true spray). The volts were adjusted up with each pass to account for the stickout change as the hole filled ending at 25.5 for the top of the holes.The whole deal with plug welding took about 3hrs for 7 welds, the 13 bores took a little more than a day counting the setup/cleanup. The time for me worrying about the plug welds = eternity... I hand wrote on the delivery ticket and conform papers "we gotta have a talk"... pics belowMatt Attached Images
Reply:Why not just machine a steel plug with a bevel and also bevel the hole and weld all around?
Reply:Drama indeed! Looks like a nice careful repair. Lotsa pucker factor there.
Reply:Originally Posted by IrishBrewerWhy not just machine a steel plug with a bevel and also bevel the hole and weld all around?