In-process weld rework during finishing of as-cast surfaces on many kinds of castings is widely misunderstood by casting materials engineers, manufacturing engineers, and inspectors. In some cases, welding is prohibited, or restricted, or significant burdens are imposed to document welded castings. This paper reviews current specifications and the results of testing done over the years on aluminum castings for aerospace, military and commercial applications. Proper welding technique and post processing recommendations are also discussed for welding of aluminum alloy castings.
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