Turbine blades made from subject castings were in need of weld repairs caused by machining errors. When blades of specific materials are used in hydro-turbine units, they exhibit excellent erosion-corrosion resistance. Because of dimensional control issues, repairs need to be completed without a post-weld heat treatment (PWHT). The purpose of PWHT is to minimize the risk of stress corrosion cracking in service, reduce residual stresses, and control the properties of the weldment. O’Donnell Consulting assisted in resolving repair procedures.