System and method to produce a structure for a weld joint using additive manufacturing

A method for forming a weld joint using additive manufacturing, the method comprising:

• providing a first non-additive manufactured metallic plate, the first non-additive manufactured metallic plate having a first thickness, a first length greater than a first width thereof, a first end portion, a second end portion opposite the first end portion, and a first middle portion between the first end portion and the second end portion;
• providing a second non-additive manufactured metallic plate, the second non-additive manufactured metallic plate having a second thickness, a second length greater than a second width thereof, a third end portion, a fourth end portion opposite the third end portion, and a second middle portion between the third end portion and the fourth end portion;
• additive manufacturing a first metallic portion permanently onto the first end portion of the first non-additive manufactured metallic plate, and not onto the first middle portion of the first non-additive manufactured metallic plate, to effectively increase a cross-sectional area of a resultant first weld joint interface formed by the first end portion and the first metallic portion, without creating any fatigue-sensitive notches;
• additive manufacturing a second metallic portion permanently onto the third end portion of the second non-additive manufactured metallic plate, and not onto the second middle portion of the second non-additive manufactured metallic plate, to effectively increase a sectional area of a resultant second weld joint interface formed by the third end portion and the second metallic portion, without creating any fatigue-sensitive notches;
• and
• welding the first weld joint interface to the second weld joint interface to create the weld joint, the weld joint having lowered stress at any toe or root as compared to a weld joint between the first non-additive manufactured metallic plate and the second non-additive manufactured metallic plate without the first metallic portion and the second metallic portion, respectively.