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A notch can cause incomplete fusion in materials by creating a stress concentration point where the material is weakened. When subjected to thermal or mechanical loads, the presence of a notch can hinder the flow of molten material during the welding or casting process, preventing proper bonding. Additionally, the geometry of the notch can disrupt the uniformity of heat distribution, leading to insufficient melting and incomplete fusion at the joint. This results in a potential failure point in the structure.

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