The corner was gouged with a cutter during rough machining. The repair must completely fill this large defect, but the heat of welding cannot be allowed to distort the part and shouldn’t disrupt the copper plug that seals a waterline in this part.
The material is 420M stainless at 52 RC.
This is about as big a weld volume as can be conveniently handled by laser micro welding. Bigger weld areas are better handled with TIG, but at the risk that the part will distort.
It is possible to do the rough welding using TIG and manage areas of distortion afterward, with the laser welder.
1. TOP VIEW: Note the huge number of individual welds required to fill this defect. (Each hemispherical mark you see, is formed by a discrete weld deposit using a 0.015” diameter 420 M stainless welding wire under argon gas coverage).
The engraving was changed per customer request.
The surface geometry to enable re-machining the insert was not available, therefore the welding needed to be delicate, allowing it to be re-finished using only polishing stones. On the left side, a logo has already been welded and hand stoned to 600 stone finish.
1. The lettering is approximately 1/8” (3.2mm) tall. The welds stand proud of the surface less than 0.003” (0.1mm). The material is P20 mold steel.