We have a jet turbine repair involving buildup (restoration) of worn surfaces on an IN 738 component, using L-605 weld wire / TIG process (are extending a flange 0.020" to 0.075". Flange thickness is 0.060-0.070"). Currently, no pre- or post-weld thermals are allowed (it is doubtful the part could be re-solutionized due to distortion concerns). A previous literature search led us to develop techniques to reduce the heat input to the base metal as much as possible (currently use a water-cooled Cu chill block, minimum amperage during welding). Would like to further reduce reworks/cracks in the HAZ. Does anyone have experience with this type of scenario, or have a feel for whether plasma arc welding would result in less cracking?