A method for forming a secondary component from an original component having an original shape, said method comprising: separating the original component into a parent component and a replaced portion; forming a replacement coupon using an additive manufacturing system, the as-printed replacement coupon shaped to substantially match the original shape of the replaced portion; and coupling the replacement coupon to the parent component to form the secondary component; wherein the method further comprises at least one of the following: removing the as-printed replacement coupon from a build plate of the additive manufacturing system prior to application of any heat treatment to the as-printed replacement coupon, wherein the as-printed replacement coupon maintains a near-net original shape of the replaced portion after removal; entering the secondary component into duty with no hot isostatic press treatment of the as-printed replacement coupon having been performed; performing a pre-weld heat treatment of the parent component and the as-printed replacement coupon at least partially simultaneously, wherein the pre-weld heat treatment is the sole heat treatment applied to the as-printed replacement coupon prior to said coupling. wherein the as-printed replacement coupon is formed from an alloy in powdered form, wherein the alloy consists of, by percentage weight: cobalt from 60 percent to 65 percent; chromium from 25 percent to 30 percent; molybdenum from 6 percent to 7 percent; and nickel from at least 0.1 percent to 1 percent; and iron from at least 0.75 percent to 2 percent; and carbon less than about 1.0 percent; silicon less than about 1.0 percent: and manganese less than about 1.0 %. separating the original component into a parent component and a replaced portion; forming a replacement coupon using an additive manufacturing system, the as-printed replacement coupon shaped to substantially match the original shape of the replaced portion; and coupling the replacement coupon to the parent component to form the secondary component; wherein the method further comprises at least one of the following: removing the as-printed replacement coupon from a build plate of the additive manufacturing system prior to application of any heat treatment to the as-printed replacement coupon, wherein the as-printed replacement coupon maintains a near-net original shape of the replaced portion after removal; entering the secondary component into duty with no hot isostatic press treatment of the as-printed replacement coupon having been performed; performing a pre-weld heat treatment of the parent component and the as-printed replacement coupon at least partially simultaneously, wherein the pre-weld heat treatment is the sole heat treatment applied to the as-printed replacement coupon prior to said coupling. wherein the as-printed replacement coupon is formed from an alloy in powdered form, wherein the alloy consists of, by percentage weight: cobalt from 60 percent to 65 percent; chromium from 25 percent to 30 percent; molybdenum from 6 percent to 7 percent; and nickel from at least 0.1 percent to 1 percent; and iron from at least 0.75 percent to 2 percent; and carbon less than about 1.0 percent; silicon less than about 1.0 percent: and manganese less than about 1.0 %. removing the as-printed replacement coupon from a build plate of the additive manufacturing system prior to application of any heat treatment to the as-printed replacement coupon, wherein the as-printed replacement coupon maintains a near-net original shape of the replaced portion after removal; entering the secondary component into duty with no hot isostatic press treatment of the as-printed replacement coupon having been performed; performing a pre-weld heat treatment of the parent component and the as-printed replacement coupon at least partially simultaneously, wherein the pre-weld heat treatment is the sole heat treatment applied to the as-printed replacement coupon prior to said coupling. wherein the as-printed replacement coupon is formed from an alloy in powdered form, wherein the alloy consists of, by percentage weight: cobalt from 60 percent to 65 percent; chromium from 25 percent to 30 percent; molybdenum from 6 percent to 7 percent; and nickel from at least 0.1 percent to 1 percent; and iron from at least 0.75 percent to 2 percent; and carbon less than about 1.0 percent; silicon less than about 1.0 percent: and manganese less than about 1.0 %. cobalt from 60 percent to 65 percent; chromium from 25 percent to 30 percent; molybdenum from 6 percent to 7 percent; and nickel from at least 0.1 percent to 1 percent; and iron from at least 0.75 percent to 2 percent; and carbon less than about 1.0 percent; silicon less than about 1.0 percent: and manganese less than about 1.0 %.