Abstract: In one embodiment, the present invention relates to a method and system of determining the weld bead sequence on a mechanical component is disclosed. In one specific embodiment, the sequence is determined by numerical analysis of a plurality of weld bead sequences to determine the weld bead sequence. Then, after this sequence is determined, a weld overlay is placed onto the mechanical component using the sequence. In particular embodiments, a weld bead sequence is applied to a boiler tube panel wherein the sequence begins at the crown of the tube, progresses down the walls of the tube to the tube and membrane interface, and concludes on the membrane. The new bead sequence reduces residual and distortional stresses as created by applying a weld overlay.