Abstract: There is provided a method of applying a weld overlay to a surface of a wastage susceptible chamber. The basic steps of the method include evaluating the post weld orientation of the surface of the wastage susceptible chamber resulting from the movement of the surface in response to the application of a weld overlay thereon and selecting characteristics of a weld overlay to be applied to the surface of the wastage susceptible chamber based upon the step of evaluating the post weld orientation of the surface of the wastage susceptible chamber. The basic steps of the method also include determining a series of weld torch engagement locations relative to the surface of the wastage susceptible chamber at which a weld torch is to be located for performing thereat welding operations which result in a weld overlay on the surface having characteristics corresponding to the predetermined weld overlay characteristics.