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Has anyone else encountered this? If so 1. Is a weld repair possible? 2. If not, are there any possibilities other than a new deck ($700. according to Hustler dealer)?

That can easily be welded. May just need some paint afterwards.
You'll have to take it off to weld probably though.

If you cant find a welder, you could probably bolt that piece back on. Drill holes on the edge. Use grade 8 and put many bolts. At least 8.

Several years ago noticed crack at left front of deck. removed deck & took to local machine shop to be welded, they did not charge much & did excellent job.

Make sure you find a good welder who knows what they are doing. Too much heat in an area will cause deck to warp and it will not cut even.

Ouch! Yeah, get it welded or do it yourself. Please post an "after" pic.

And we will need the story of how that happened. Did you hit something or did it just fail?

That’s just crazy.