Oxy-fuel weld repair of metallic components

A method of repairing a cast iron cylinder head having at least one valve seat pocket machined into a combustion deck surface of the cylinder head, and at least one fuel injector bore machined through the cylinder head and opening on the combustion deck surface, the method comprising:

• inspecting the cylinder head along the combustion deck surface to identify defects in the cylinder head;
• machining away sufficient material from an area of the identified defects to eliminate the defects;
• reinspecting the cylinder head to verify that all of the identified defects have been removed;
• machining away a portion of the fuel injector bore adjacent the machined away area that included defects;
• turning the cylinder head over with the combustion deck surface facing down;
• machining a spot face in the fuel injector bore to create a land adjacent the machined away portion of the fuel injector bore;
• inserting a plug made of a high-temperature-resistant material into the fuel injector bore to seal against the land;
• turning the cylinder head back over with the combustion deck surface facing up;
• oxy-fuel welding weld material that is substantially the same as the material of the cylinder head to at least fill in the machined away area that included defects and the machined away portion of the fuel injector bore;
• and
• final machining areas that have been welded.