Systems and methods for adding material to castings

A method for depositing material on a component, the method comprising:

• forming an excavation in a target area of the component;
• applying an interface layer on the excavation by flowing the interface layer on the excavation or by spraying a thermal spray on the excavation;
• and
• forming a first layer of a first material deposit on the interface layer.

A system comprising:

• a controller;
• an excavation machine coupled to the controller, the excavation machine comprising an excavator configured to selectively remove material from a component so as to form an excavation;
• a pretreating machine coupled to the controller, the pretreating machine comprising a pretreater configured to selectively form an interface layer on the excavation by spraying a thermal spray on the excavation;
• and
• an additive manufacturing machine coupled to the controller, the additive manufacturing machine configured to selectively form a first deposit of a first amount of material on the interface layer.