• Multistage solution treatment effectively eliminates eutectic phases and carbides in nickel-based single crystal superalloys.
• Longer aging holding time (10 min vs 5 min) results in larger and more rectangular γ' precipitates.
• Water cooling induces secondary γ' precipitates, affecting the final microstructure.
• Phase field simulations reveal that lattice mismatch-induced coherency stresses and elevated stress triaxiality along 〈111〉 drive γ' rectangularization.
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