Cladding of alloys using flux and metal powder cored feed material

A method comprising:

• melting a feed material comprising a hollow metal sheath containing powdered core material onto a substrate to form a layer of a desired superalloy cladding material under a layer of slag;
• wherein the metal sheath comprises an extrudable subset of elements of the desired superalloy material, and the powdered core material comprises powdered metal and powdered flux that complete the elements of the desired superalloy material when melted together with the sheath;
• and
• allowing the superalloy cladding material and slag to cool, then removing the slag to reveal the layer of desired superalloy cladding material.

A method comprising:

• melting a feed material electrode comprising flux and powdered titanium onto a substrate to form a layer of cladding material using a cold metal arc welding torch;
• and
• applying a shielding gas comprising oxygen or carbon dioxide during the step of melting;
• wherein an amount of the powdered titanium is selected to compensate for an amount of titanium lost to the layer of cladding material by reaction with the oxygen or carbon dioxide.