Abstract: A method for inspecting a repair insert welded into a hole where the weld is not permitted to penetrate the full depth of the hole. An inspection feature, either grooves at the minimum and maximum weld depths or grooves parallel to the insert axis, is formed on the surface of the repair insert. The insert is welded into the hole using electron beam or laser welding. The structure is then non-destructively inspected to determine whether the inspection feature has been consumed at the minimum required weld depth and has not been consumed at the maximum permitted weld depth.