This is for the Ali welding idea.
Is essentially an all-weld-metal testpiece, but reasonably realistic for thermal cycle, the welding condition the welder was presented with making the sample / test-piece, etc.
This is aiming for radiography - but backed-up by side-bends given some inter-run lack-of-fusion might not show up on X-ray so know an apparently good weld on X-ray is good in all regards.
Sketch / drawing...seen on this page where that drawing features... Uses edge of a thick plate as "substrate", with couple of held-on slightly "sticking up" plates to create groove. One good point is to extract the all-weld-metal sample (with a bit of remnant plate at the sides), put the welded sample in a saw and make a simple cut. Which also "regenerates" the rest of the plate material for immediately using on the next test.
Idea is to get a fair amount of weld per sample so can see the *median* result from the welding strategy. Ignore a bit of the worst; disregard a bit of the best and see what the main story is on weld cleanness when doing it that way. Anyone who has a "magic weave" or a "magic setting with my 'Throbatron Supa-Doopa'" which solves everything - show us...
So yes, thoughts?
Regards, Rich Smith