This work presents a study on the bead deposition planning strategy in order to allow the use of robotic welding on the task of lling the crack removal cavity. Therefore, when thinking about dening the necessary sequence and the distribution of weld beads to ll the cavity with metal, such that the deposition process can be robotized, some problems arise related to the bead section geometry dependence on the welding parameters and on the welding position. Such geometry will strongly inuence the number of layers of weld beads needed, considering that the lling process is carried out in layers. In this case, the rst problem to be faced is the denition of the distance between parallel beads necessary for the deposition of a at weld layer. The second problem is the layer thickness that results from the selected distance between parallel beads within a layer. This work, therefore, addresses the two previously cited problems by developing statistical models that can map the bead section geometry variations due to changes in welding parameters for the pulsed GMAW process. Then this methodology denes the strategy to determine the trajectory of weld beads of each layer in order to perform the geometric evaluation of the recovery and quality of the lling. Practical results of geometric point of view of the strategy of lling, applied to a cavity such as the one resulting from the removal of a crack are presented in order to validate the proposed methodology.