WELD REPAIR HOW TO WELD REPAIR BIGGEST MACHINING MISTAKES

[thruwall]

How would you go about welding this machine shop fabrication thruwall drill hole in a thin wall 904 material turbine caising. I guess the machine shop doesnt know which side is port and which side is starboard, they drilled for fabrication on the wrong side of the casting. Your thoughts on how to go about rewelding the thruwall hole 100% x-rayed. Its a 1-1/2" diameter hole drilled on a raised stepped boss on the outside of the casting, the inside of casing has been machined with grooves already, so the drill thru has taken out 3 sections in the machined grooves. To make matters even worse, its a SSN PROTOTYPE.

 

[enginesrus]

How thick is the material in that area?
You could make a plug that threads into the hole and then weld it (may not work for weld penetration). Or just a plug with no threads. Depends on the thickness of the materials and how much penetration you want. The best weld maybe an electron beam welding process. And likely very expensive. The proper thing to do for the machine shop would be a taped on marker to show where you needed the hole or for orientation.
It may be possible to match the machined grooves on the plug that is used to fill the hole, none of this will be fast nor cheap to do. And hopefully the opening into the area that is machined with grooves is large enough to gain access to. Keep us posted on how it goes.

 

[thruwall]

Thickness is a little over 2" plus the depth of the groove walls. Has to be full penetration weld 100% RT. Heres a better view or drawing on what has to be done.

 

[thruwall]

Its been welded and cleared thru the x-ray dept and on its way back to machine shop for "PORT" side fabrication drill thru?