Hello Im new here, very interesting reading, I have no experience with eastern wootz type material, but would surmise a great deal of material loss at high welding heats, especially with thin broad sections like you would find on a ground and already formed blade, you would be very apt to burn off the sides especially the thin cutting edge. I would think silica sand would need too high a heat to do this sort of repair on a thin and high carbon workpiece.
The fire would need to be deep and of a reducing nature (ie charcoal) a slow and steady blast. The back edge of the blade would face the tue iron (air input) and the thin delicate edge face away from the air input to minimise burn off. I would think , but I have never tried this.. I think I would end up cutting it all up re stacking and re welding the entire billet !!!
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