A method of repairing an airfoil blade involves the steps of providing an airfoil blade have a leading edge, a trailing edge, a tip and a base. A length of the airfoil blade is defined by the tip and the base and a width of the airfoil blade is defined by the leading edge and the trailing edge. A weld is made along a first direction of the length of the airfoil blade and then made in a second direction along the width of the airfoil blade to form a first weld layer. The first weld layer has a first portion extending across the length of the airfoil blade and a second portion extending across its width. A second weld layer is welded onto the first layer such that an end wall of the second weld layer abuts the second portion of the first weld layer.