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So this may be a bigger problem. Than is just the visible cracks. The question is are some of theses defects are in the parent material as well. Or was it initiated by poor welding procedure.. a deep dive into the details and how were they fabricated and how were NDT tested. Cracks could have...

Op An important procedure regardless of configuration. Is to fit up the welded assembly. Generally some type of fixture or alignment tools, set in place then tack welded in place. Machined parts are easier. Sheet metal are more difficult. Many times details have to be straightened, presses...

When I was a young man , working in a sheet metal shop fabricating tube and pipe. There was hydrostatic testing required on the individual section of various exotic pipe section for the petrol and chemical industry. I do not recall the specifications, but I tested upto 2000 psi. With no...

All great information and great brain storming. I want throw my 2 cents in the subject. As I had many years in a sheet metal shop while not directly related. There was lots of weld and NDT, and pressure testing. We had some of the best welders . And were very good at their jobs. But depending on...

Electro polishing is a great way to polish parts. But not advisable for close tolerance dimensions. Any time pats are heated over 800 degrees F Parts will obtain light scale. On rough out parts parts are eighter vapor blast for close dimensions, or abrasive blast on roughed parts. Abrasive...

Op If part are not protect while heat treatng will have damage on the surface. Did not mentioned these parts appear that it was run in vacuum or and protective atmosphere. Parts should be semi finished then after heat treat then should be finished machined.

Gp Hard to say don't know the configuration. Options 1) add weld tabs with alignment holes Have match drilled or jig bored for tooling. Then after welding machine off. 2) drill and ream .250 diameter holes Use for alignment, then plug weld after

Elvis has left the building

I watched that video while back, and was amazed in the lack of calibration or not precise Torque values . Keep in mind an old style non click Torque wrench unless careless damage never loses calibration. And it is in my tool box to this day. My mechanic days are been less and less these days.

It's interesting subject and as a home mechanic for most of my simple lifespan. As a young mechanic I broke all the rules. Disassembling and reassembling countless Vehicles, engines , motorcycles, small engines and on . Never use to use a Torque wrench. Of course I know better now. However it...

Op I don't make quick response so I took time to answer. Yes a minimum fillet radii at root, is a must. Contact stress if not sufficient it will cause pitting and Crack propagation. Tooth bending will cause failure at the root. Stay below the SN cycles. For the material chosen. For the required...

Op Both designs are bad, but yours will cause more issues as mention before. Changing gear boxes because lt look not right is not a way to approach this. You need more coaching on gear box designs. And need more experience. While the first design has a long small diameter shaft, could fail due...

Op AGMA is conservative because it's used for Aerospace, and heavy industrial uses with high Torque and rpm values. The material is chosen for contact stress, Loads on gear tooth flanks, and bending fatigue. Your application is medium high rpm. But you gave no Torque values. AGMA quality...

OP NDT heavy stress areas or joints. Verify if there are areas that have plastic deformation. And verify for indications . Which would indicate damage and failure. I agree there should have been a procedure for stress strain sensors or gages. Remove and replace sections and test with Tensile...

Op Please provide the required Torque and rpm In and out. AGMA is proven calculations. Why was 15-5 chosen

It's a little confusing, what are the units and size of the beam. Is there a method to double verify results

Yes measure the actual results from the load

Yes it appears what the OP objective may not be practical. The answer may well be a mechanism or machine.

Measure the elasticity, prior to plastic deformation. And failure. Do a 3D model first.

This way out of my league. That said why not calculated as rb said. Calculate the beam configuration. Do a manual test under load, measure the actual deflection. Use sensors To measure the movement or moment. Is that practical.