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A containerless method of producing a crack free metallic article of near-net shape includes melting a filler material into a metallic substrate or seed under conditions chosen to preclude cracking. In a preferred embodiment of the invention, a laser beam is operated at a relatively low power densit

A containerless method of producing a crack free metallic article of near-net shape includes melting a filler material into a metallic substrate or seed under conditions chosen to preclude cracking. In a preferred embodiment of the invention, a laser beam is operated at a relatively low power density and at a relatively large beam diameter at the substrate surface for an extended length of time to produce a molten pool with a low aspect ratio. Near-net shape is achieved by applying the process in a closed-loop, multi-axis material deposition system.

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[ What is claimed is:] [1.] A single crystal metallic article made with the use of an energy source, the method comprising melting a filler material into a single crystal metallic substrate having a single crystal structure under conditions chosen to eliminate cracking, namely low power density betw

[ What is claimed is:] [1.] A single crystal metallic article made with the use of an energy source, the method comprising melting a filler material into a single crystal metallic substrate having a single crystal structure under conditions chosen to eliminate cracking, namely low power density between about 10 watts/cm.sup.2 and about 10.sup.4 watts/cm.sup.2, and at a relatively large diameter between about 0.1 inches and about 4 inches, for an extended length of time between about 0.1 seconds and about 1000 seconds to produce a molten pool with a low aspect ratio, wherein the single crystal structure of the substrate is continued throughout the article to produce a crack free article having a dendrite spacing between about 20 microns and about 180 microns.