A method for manufacturing a thermally deformable component for high thermal loads, includes: providing a first area of the component with a first metallic material by a generative laser process, or making the first area of the first metallic material; providing a second area of the component with a second metallic material by a generative laser process, or making the second area of the second metallic material; where at least one of the metallic materials is deposited by the generative laser process, and a ratio of a linear expansion coefficient .sub.1 of the first metallic material and of a linear expansion coefficient .sub.2 of the second metallic material is as: $\frac{{}_2\left(T_2\right)}{{}_1\left(T_1\right)}=x\frac{.Math.T_1-T_0.Math.}{.Math.T_2-T_0.Math.},$
where x=0.5 to 1; T.sub.1=mean operating temperature on a hot side; T.sub.0=reference temperature; T.sub.2=mean operating temperature on a cold side.

A process for brazing of aluminium magnesium alloys is described applying a flux which comprises KAlF.sub.4 or CsAlF.sub.4 or both as major constituent. The flux further comprises at least one alkaline or alkaline earth metal compound selected from the group consisting of KAlF.sub.4, CsAlF.sub.4, Li.sub.3AlF.sub.6, CaF.sub.2, CaCO.sub.3, MgF.sub.2, MgCO.sub.3, SrF.sub.2, SrCO.sub.3, BaF.sub.2, and BaCO.sub.3. Preferably the flux comprises or consists of KAlF.sub.4, CsAlF.sub.4, and Li.sub.3AlF.sub.6 and optionally contains also BaF.sub.2.

The present disclosure relates to new metal powders for use in additive manufacturing, and aluminum alloy products made from such metal powders via additive manufacturing. The composition(s) and/or physical properties of the metal powders may be tailored. In turn, additive manufacturing may be used to produce a tailored aluminum alloy product.

A flux (55) for superalloy laser welding and additive processing (20, 50), including constituents which decompose when heated in a laser induced plasma or to a melt temperature of the superalloy (42), creating one or more gases (46) that blanket the melt to protect it from air, while producing not more than 5 wt. % of slag relative to the weight of the flux. Embodiments may further include compounds providing one or more functions of surface cleaning, scavenging of impurities in the melt, and elemental additions to the superalloy.

A method and resulting gas turbine engine component (40) having a protective layer of metallic glass (14) deposited over a superalloy substrate (12). A further layer of ceramic insulating material (42) may be deposited over the metallic glass. The metallic glass functions as a bond coat to provide thermal insulation and mechanical compliance. The metallic glass may be deposited onto the substrate by a flux mediated laser deposition process wherein powdered alloy material (18) is melted together with powdered flux material (20). The flux material can facilitate the glass forming process by adding to the solidification confusion effect and/or by providing an active cooling effect.

A flux-cored wire may be used with an ArCO.sub.2 mixed gas, the wire having a steel sheath filled with a flux. Such flux-cored wires may include, as a total of the steel sheath and the flux, relative to a total wire mass: Fe in 92 mass % or more, total Si in a 0.50 mass % or more and 1.50 mass % 15 or less, Mn in 1.00 mass % or more and 3.00 mass % or less, total Li in 0.010 mass % or more and 0.10 mass % or less, and total Mg in 0.02 mass % or more and less than 0.50 mass %, C in 0.15 mass % or less, P in 0.030 mass % or less, S in 0.030 mass % or less, and a slag forming agent in 0.50 mass % or less.