Metal additive manufacturing processes are currently used to fabricate complex metal part shapes while maintaining mechanical properties comparable to those fabricated via traditional means of cast and wrought processes. Increased deposition rates, repairing capability via cladding and the ability to produce near-net-shaped parts have significantly increased the adoption of directed energy deposition (DED) for fabricating and repairing parts; however, a significant challenge exists when planning to alter the deposited metals’ microstructure and mechanical properties if they involve in-situ alloying during deposition because we are unable to achieve the required material properties based on the unavailability of pre-alloyed powders used for AM processes. Zirconium (Zr) alloys are widely used for ATF cladding in LWRs; however, increased corrosion may occur due to contact with specific metallic components, such as Pt, Hf, Inconel also known as ‘shadow corrosion’. Zr alloy-based parts have multiple disadvantages, including hydrogen absorption in Zr during fuel operations, resulting in embrittlement and fuel rod failure. These observations have inclined us to select the FeCrAl as the primary material for the proposed research but the major findings from this research can be utilized to other alloy families and different application sectors outside nuclear energy.