Method of aluminizing metal alloys by weld overlay using aluminum and aluminum alloy filler metal

A process for coating a substrate, comprising:

• providing a metallic substrate formed from a metal selected from the group consisting of iron based alloys, cobalt based alloys, nickel based alloys, titanium based alloys;
• forming a metallic pool on said substrate by applying energy thereto to melt said metal of said substrate;
• adding aluminum or an aluminum based alloy to said pool;
• melting said aluminum or aluminum alloy in said pool to form an alloy insitu with said metal of said substrate;
• forming a weld deposit of an alloy formed from said aluminum or aluminum base alloy and said metal of said substrate;
• said weld deposit having an average thickness of about 3 mm and exhibiting no segregation from said metal substrate.