Ha Ha, thanks. I am the welder. I think we can weld it, it's just that the fillet will end up being too big. I think we are just going to end up welding it and then machining it down so the next piece will fit in. I am expecting that after the machining op there's a good chance it will leak though. I don't know what else to try and if we can't get it leak tight then they will be forced to redesign it. I just was curious if there was another process besides GTAW that might get better results before we try to weld it manually. I know essentially nothing about ebeam, laser, plasma, etc. and wanted to reach out to vendors that do that, but there doesn't seem to be organizational support for that. Didn't know if anything like that would be feasible. I gave them my opinion and voiced my concerns so I think we'll just go for it and see what happens. Thanks.
Lawrence, where did I beat up the poster? I said the weld detail is bad. "A sow's ear is a sow's ear regardless of what you call it" is hardly a shot at the poster.
Why put the onus on the welder? Redesign the assembly to provide proper access.
Al