NOVELTY - Application of dense crack-free coating involves forming a suspension comprising first and second material compositions in a carrier medium; depositing suspension onto surface to form a layer; and controllably heating the layer to at least20 degreesC above the melting temperature of second material composition, but not more than 20 degreesC below the melting temperature of the first material, to dissolve some of first material in melted second material composition.    USE - For application of a dense crack-free coating, used to repair or build complex structures, such as fuel cells, sensors, and turbine components, such as airfoils, angel wings, vanes and shrouds (all claimed).    ADVANTAGE - The combination of first and second materials and controlled heating step provides an alloyed homogeneous phase coating or built structure once the density reaches or exceeds 96% of the theoretical density (less than 4% residual porosity).    DETAILED DESCRIPTION - Application of dense crack-free coating involves:    (a) selecting a first material with a first melting temperature and a second material composition having a second melting temperature at least 40degreesC lower than the first melting temperature;    (b) forming a suspension (34) comprising the first material and second material composition in a carrier medium;    (c) depositing the suspension onto a surface to form a layer; and    (d) controllably heating the layer to at least20 degreesC above the melting temperature of the second material composition, but not more than 20 degreesC below the melting temperature of the first material, to dissolve at least some of the first material in melted second material composition.    INDEPENDENT CLAIMS are also included for:    (a) A composition of matter, comprising a first material with a first melting temperature and a second material composition having a second melting temperature at least 40degreesC lower than the first melting temperature and a carrier medium; and    (b) A structure comprising consecutively deposited free-form lines comprising a ceramic composite hot gas path turbine component (e.g. turbine airfoil comprising a blade tip, an interconnect for a fuel cell, or property-measuring sensor) repaired by depositing a free-form line, and produced by selecting a first material with a first melting temperature and a second material composition having a second melting temperature at least 40degreesC lower than the first melting temperature; forming a suspension comprising the first material and second material composition in a carrier medium; depositing the suspension onto a surface to form a layer; and controllably heating the layer to a temperature at least 20 degreesC above the melting temperature of the second material composition, but not more than 20 degreesC below the melting temperature of the first material, to dissolve at least some of the first material in melted second material composition.    DESCRIPTION OF DRAWING(S) - The figure shows a part that is repaired by the above method.    Material depositing device (14)    Piston (26)    Airfoils (30)    Suspension (34)    Forming surface (36)