Welding and repair welding are an essential process in the fabrication of most structures. When a structure is in need of a repair is must be done properly so that it will have equivalent static strength, ductility, fracture toughness and fatigue strength levels as the base structures. Repair welding, like many other things, can be done in one of two ways, it can be carried out as a logical procedure that ensures the production of a usable and safe component, or it can be done in a more haphazard manner. The latter approach results in poor-quality workmanship that can land all the parties involved in hot water with issues such as failed parts, large warranty claims, dissatisfied customers and in some cases cause serious injury.