Method of repairing a component using an additive manufacture replacement coupon, and alloy for additive manufacturing

The invention discloses a method of repairing a component using an additive manufacture replacement coupon, and an alloy for additive manufacturing. The method includes separating (504) the original component (300) into a parent component (302) and a replaced portion (308), and forming (508) a replacement coupon (402) using an additive manufacturing system (400). The replacement coupon (402) is shaped to substantially match the original shape of the replaced portion (308). The method (500) further includes coupling (516) the replacement coupon (402) to the parent component (302) to form the secondary component (301). The method (500) also includes at least one of (i) removing (512) the replacement coupon (402) from a build plate (401) of the additive manufacturing system (400) prior to application of any heat treatment to the as-built replacement coupon (402), wherein the replacement coupon (402) maintains a near-net original shape of the replaced portion (308) after removal, and (ii)entering (524) the second