# Methodology for Verification of Geometrically Complex Components Through Reverse Engineering
## 2 Materials and Methods
### Manufacturing of the Prototype and Processes Related to Welding, Assembly, and Surface Treatment  
During the manufacturing of the prototype welding fixture, several key phases were followed to ensure the precision and functionality of the final product. To prevent potential bending errors and achieve the required accuracy in the production of the welding fixture, a specific methodology was chosen, focusing on precise processing and component assembly. No materials requiring subsequent bending were used in the manufacturing process; instead, laser-cut parts were employed. This production method enabled high accuracy, minimizing geometric deviations and ensuring a quick alignment of individual components during assembly. The components that were later assembled into the welding fixture were designed with interlocking features, ensuring precise geometric accuracy during  
Figure 7: Prototype of the rotating welding fixture structure. assembly while reducing the risk of assembly errors. These interlocks acted as positioning guides, ensuring the correct placement of components, thereby eliminating the risk of misalignment. After welding, toggle clamps and positioning stops were added to the fixture to provide stability, correct positioning, and accuracy throughout the entire welding process. For quick assembly and potential adjustments after prolonged use, these elements were fastened using bolted joints. This fastening method was selected for its flexibility and precision, allowing for the fine-tuned positioning of individual components to achieve the stability and accuracy necessary for proper part alignment. Furthermore, during the fixture design phase, particular emphasis was placed on minimizing thermal defects in the heat-affected zone (HAZ), which could later impact the quality of the weld. By ensuring precise and stable fixation of components, the risk of material deformation during welding--caused by improper clamping or excessive heat input--was effectively eliminated. As can be seen in Figure 8, this approach resulted in a high-quality and precise outcome, fully prepared for the subsequent production stages. During verification, sheets of various thicknesses, ranging from 4 to 5 mm, were used, and welding was carried out using the MAG (Metal Active Gas) method. During the process, it was necessary to minimize thermal effects that could lead to deformation or excessive internal stress. The first step was to properly clamp the sheets to prevent movement during welding. Initially, tack welding was performed at regular intervals, which fixed the material in the desired position and reduced twisting during the later application of the main weld. When welding larger parts or joining sheets of different thicknesses, we selected procedures that ensured an even distribution of heat. Instead of welding in a single line, we applied a backstep welding procedure, where welds were placed in the opposite direction to prevent heat from concentrating in one area. This prevented excessive elongation of the material in one direction and minimized twisting. Figure 8: Manufactured prototype of the welding fixture. An important factor was also controlling the heat input. We used a welding wire with a diameter of 1.0 mm, suitable for sheet thicknesses in the range of 4 to 5 mm, and worked with a welding current of 140 to 180 A and a voltage of 18 to 22 V. The average wire feed speed was 6 to 9 m/min, ensuring a stable melting process and optimal penetration of the weld metal into the base material. To protect the welding area from oxidation and contamination, a mixture of protective gases, CO2 and Ar, was used, with a higher CO2 content (approximately 18 to 25%) supporting good penetration of the weld metal and a stable electric arc. Short breaks were made between individual welds to allow the material to cool naturally and prevent excessive heat buildup. Finally, the fixture underwent surface treatment, specifically coating and painting, to protect it from external influences such as corrosion, scratches, and chemical exposure.