Patent ID: 7126076

Claim:
A method for repairing a defect in a metallic substrate using welding, the substrate having a first surface and a second surface, the method comprising: a) placing a consumable filler slug in contact with the defect; b) placing a sacrificial retainer in contact with the consumable filler slug; c) transmitting electrical current from a first electrode to a second electrode for a period, thereby resistively heating the consumable filler slug, the sacrificial retainer, and the metallic substrate resulting in coalescence in a substantially liquid pool that substantially fills the defect wherein a portion of the sacrificial retainer remains solid and constrains flow of the pool and seals the pool from a surrounding atmosphere, the first electrode and the second electrode applying pressure to the substantially liquid pool; d) cooling the substantially liquid pool to solidification under the pressure of the first electrode and the second electrode producing a repaired metallic substrate; and e) removing the first electrode and the second electrode from contact with the repaired metallic substrate.