Consumable insert for welding

A method for welding a first component and a second component, the method comprising:

• placing the first component and the second component in such a manner that a gap is defined between adjacent surfaces thereof;
• scanning a profile of the gap between the adjacent surfaces;
• preparing a three dimensional model corresponding to the scanned profile of the gap;
• forming, by three dimensional printing, a body and a dam portion of a consumable insert, such that a profile of the body and a profile of the dam portion is based on the three dimensional model;
• aligning the body and the dam portion with respect to the gap between the adjacent surfaces;
• and
• welding the body and the dam portion with the adjacent surfaces such that the body and the dam portion is consumed, at least in part, into a weld puddle.

A method for forming a consumable insert for welding a first component and a second component, the method comprising:

• scanning a profile of a gap between adjacent surfaces of the first component and the second component;
• scanning corresponding surfaces of the first component and the second component respectively;
• preparing a three dimensional model corresponding to the scanned profile of the gap and the scan of the corresponding surfaces;
• and
• forming, by three dimensional printing, a body and a dam portion of the consumable insert, such that a profile of the body matches the scanned profile of the gap and a profile of the dam portion matches the scan of the corresponding surfaces, wherein the formation is based on the three dimensional model.