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The repair of damaged Ni‐based superalloy single‐crystal turbine blades has been a long‐standing challenge. Additive manufacturing by an electron beam is promising to this end, but there is a formidable obstacle: either the residual stress and γ/γ ′ microstructure in the single‐crystalline fusion zone after e‐beam melting are unacceptable (e.g., prone to cracking), or, after solutionizing heat treatment,...
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