Tig Welding the lug probably wont break but will the heat damage the receiver? A sleeve with the lug machined in it would work if they still make sleeves.
Max
The part of the receiver that gets hot would only be a very small part at the receiver face. Only on the bottom side, and only under heat for a short time. Tig'ed would be hotter than it would be if MIG'ed for sure, but certainly not unsafe. Remember, the steel used to make that receiver (chrome moly situation) would have been subjected to a draw cycle of >400F for at least an hour. Between 400-1000 depending upon what properties the action maker wanted from the steel. So, even if you went that high for a short time, you've probably not changed anything substantially. Furthermore, the area being welded is not under a tensile load (pull), it is a compressive load. So, if any part did get weakened, as long as it doesn't crush, it's just as good as it ever was. Well, it's not going to crush.
You have to hit around 1200F for 4100 series to anneal, then slow cool. If you're talking about "Prehard", and very likely that's what would be used for receivers, that may have been drawn at up to 800-900, possibly even up to 1000. Now you're really talking about a very hot part not seeing any change.
Even if an entire receiver went to 1000F, I still don't think I'd be concerned. The safety margin is so big (mechanically), andthat temp is withing the range of recommended draw (normalizing) temps. It would still be plenty safe. In other words, I would be ok with a receiver that had been so hot it had gone through a complete (and irreversible) color change due to heat. Even if you were taking about PH Stainless, temps up to 4 digits F will still not be detrimental, as long as you don't go any more than 1000F.
Of course, this is just my opinion, and opinions vary.
/EDIT
Using hindsight and having built a few custom rifles before, I cannot imagine undertaking a project like this and using a piece of crap factory action. Just buy a nice custom that has no recoil lug. By virtue of the fact you are considering more than one barrel, you've already told me cost is not really an object. Then, why bother throwing good money after bad? Nobody is going to do this work for free, so that cost has to be considered. Any factory rifle has some value at resale, so add that amount to it. Now add $200 more and you've got a custom action that requires less additional gunsmith work, and does not have the mechanical pitfalls of a recoil lug. It's also nicer to own and use! So, even if you already own the donor action, it's penny wise and pound foolish to use it. If another $200 or $300 is going to change your lifestyle, don't build the rifle....
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