Laser deposition and repair of reactive metals

A process, comprising:

• applying a laser beam to a flux composition that covers a powdered filler material, such that the laser beam simultaneously melts the flux composition and the powdered filler material to form a melt pool;
• and
• allowing the melt pool to cool and solidify to form a resulting alloy layer covered by a slag layer,
• wherein:
• the flux composition comprises a metal halide;
• the flux composition does not comprise a metal oxide;
• and
• the powdered filler material comprises a reactive metal.

A process, comprising:

• (i) heating a flux composition with a laser beam such that the flux composition reacts upon contact with the laser beam to form a plasma and a shielding gas;
• (ii) controlling an amount of energy applied to the flux composition to convert the flux composition into a molten slag blanket in the presence of the shielding gas without completely melting a powdered filler material situated below the flux composition, such that the molten slag blanket then heats and melts the powdered filler material by thermal conduction in the presence of the shielding gas to form a filler melt pool covered by the molten slag blanket;
• (iii) allowing the molten slag blanket to cool and at least partially solidify into a solid slag layer covering the filler melt pool;
• and
• (iv) allowing the filler melt pool to cool and solidify into a resulting alloy layer covered by the solid slag layer;
• wherein the powdered filler material comprises at least 50 percent by weight of a reactive metal selected from the group consisting of aluminum, magnesium, titanium and zirconium, relative to a total weight of the powdered filler material.