Weld Distortion on Al 6061

Heat and the addition of filler metal will cause distortion.

It sounds like you are welding inserts on a post centered radially on the disk. It tue onserts are far enough from the disk and the weld is done well keeping heat and filler to the minimum necessary, the distortion might not reach the flat large part of the disk.

Be aware that attempts to minimize or eliminate distortion via rigid restraint of workpiece during welding will likely have the opposite of the intended effect.

The pin bores are near the outer diameter (the periphery) of the disk.

The remaining wall to the disk outside diameter at 1/8" bore is near 0.060" with the insert just near 0.040"

Can you post a picture?

How many do you have to do?

Is your welder (person) really good?

Maybe by heating the entire assembly to 8-900°F before/while welding?

Trial and error is called for here, maybe.

It might be ok if the holes are opposite each other...If you can balance the heat on both sides they might cancel out any noticeable warpage...but what are your tolerances?

Why not remachine the whole thing afresh?

Indeed.

That is certainly an option. Thank you, and to all of you.

If I have to throw it away I might as well try welding first.

Is there such a thing as micro welding AL 6061? Copper tubing can be braced where the solder enters the gap through capillary action. It would be nice if AL would work the same way at a lower heat/temperature than welding. Making a new one is always in the cards.

There is low temperature soldering for aluminum....

6061 can be dip brazed, but not without equipment and knowledge.

Everything You Need to Know About Brazing Aluminum