Method and system for additive manufacturing or repair with in-situ manufacturing and feeding of a sintered wire

A system for additively manufacturing and/or repairing a superalloy component via laser metal deposition utilizing a sintered wire, comprising:

• a pressure vessel connected to a powder feed system for delivering at least two powders to a powder mixing zone of the pressure vessel;
• a heating device contained within the pressure vessel, the heating device configured to heat a mixture of the at least two different powders mixed in the powder mixing zone so that liquid phase sintering occurs creating a sintered wire;
• a laser wire welding system, comprising:
• a laser energy source operably configured to direct a laser energy towards a base material for forming a melt pool thereon and for laser processing the sintered wire deposited into the melt pool for forming a layer of additive material on the base material, and
• a welding head for receiving the sintered wire directly from the pressure vessel,
• wherein the sintered wire is continuously fed from the pressure vessel to the laser wire welding system.