US Patent 9352419 Laser re-melt repair of superalloys using flux

A method of repairing service-induced surface cracks (92) in a superalloy component (90). A layer of powdered flux material (100) is applied over the cracks and is melted with a laser beam (98) to form a re-melted zone (104) of the superalloy material under a layer of slag (106). The slag cleanses the melt pool of contaminants that may have been trapped in the cracks, thereby eliminating the need for pre-melting fluoride ion cleaning. Optionally, alloy feed material may be applied with the powdered flux material to augment the volume of the melt or to modify the composition of the re-melted zone.