Repair of EDM induced surface cracks by pulsed electron beam irradiation

► For the first time the mechanism of crack repair via large-area electron beam irradiation is elucidated. ► Surface cracks are shown to be entirely eliminated in the newly remelted layer. ► The change in surface crack density and average length is quantified against process variables. ► The newly remelted layer is characterised and its depth quantified. ► Crystalline texture can be introduced at the surface by repeated shots of pulsed electrons.