Abstract: A base structure is clad and coolant channels are formed through the cladding and into the base structure. A line of tangency relative to the outer clad surface is defined for each point thereon. Linear rows of a metal feedstock are directed towards and deposited on the outer clad surface as a beam of weld energy is directed to the metal feedstock so-deposited. The metal feedstock is the same material as the cladding or one that is weld compatible therewith. A first angle between the metal feedstock so-directed and the line of tangency is maintained in a range of 20-90°. The beam is directed towards a portion of the linear rows such that less than 30% of the cross-sectional area of the beam impinges on a currently-deposited one of the linear rows. A second angle between the beam and the line of tangency is maintained in a range of 5-65°.