Porous metal coupon with thermal transfer structure for component and related component

Abstract

To provide a porous metal coupon with a thermal transfer structure for components.SOLUTION: A component 202 includes a body 206 and an additively manufactured (AM) metal coupon 200 that includes a primary member having a member porosity between 2% to 50% open space volume to total volume of the primary member. The primary member includes a first portion and a second portion distanced from the first portion by a gap. At least one thermal transfer structure, such as pins and / or fins, extends between the first and second portions across the gap. A braze material couples the AM metal coupon in a coupon opening in the body, and infiltrates into the primary member based at least on a characteristic of the member porosity. The braze material may also infiltrate the at least thermal transfer structures, which may have the same or different porosity from the primary member. The thermal transfer structures exhibit enhanced heat rejection, reduce weight of the component, and may improve component vibratory response.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to the repair or manufacture of parts, and more specifically to parts using porous metal coupons having at least one heat transfer structure. [Background technology]

[0002] Industrial components sometimes require repair. For example, hot gas path components used in turbomachinery to channel a working fluid to generate energy may require repair. Hot gas path components can take a variety of forms, such as turbine rotor blades or stationary vanes, which include airfoils that direct the working fluid to generate energy. The rotor blades are coupled to the turbine rotor and serve to rotate the turbine rotor, and the stationary vanes are coupled to the casing of the turbomachine and serve to direct the working fluid to the rotor blades.

[0003] Additive manufacturing, such as direct metal laser melting (DMLM) and selective laser melting (SLM), has emerged as a reliable manufacturing method for producing industrial parts. The advent of additive manufacturing techniques has also provided the ability to replace portions of parts, such as portions of the leading or trailing edges of a turbomachine nozzle. For example, a portion of the leading edge of a turbomachine nozzle can be removed leaving a notch in the nozzle, and a new portion (referred to herein as a "coupon") can be bonded to the notch. The coupon is additively manufactured to have a shape that at least generally matches the shape of the cutout. The coupon can replace a portion of a used turbomachine nozzle or can be added as part of a new turbomachine nozzle.

[0004] However, the replacement coupon is made of the same material and exterior construction as the removed portion of the part. As a result, the replacement coupon suffers from some of the same shortcomings as the original component and / or cutout, without the general performance characteristic improvements such as coupon strength, oxidation resistance, cycle fatigue, stress / strain resistance, ductility, wear resistance, thermal or electrical conductivity, and / or decreased mass. A single braze material is used to bond the replacement coupon to the part, which precludes the general performance characteristic improvements mentioned above, as well as additional performance characteristic improvements associated with the bond, such as increased joint bond strength and reliability, and reduced post-braze machining / blending required. Additionally, using a coupon that is materially identical to the removed cutout does not eliminate the high material cost of the replacement coupon. Summary of the Invention

[0005] All aspects, examples and features described below may be combined in any manner that is technically possible.

[0006] One aspect of the present disclosure provides an additively manufactured (AM) metal coupon for insertion into a component, the AM metal coupon comprising: a primary member having a member porosity between 2% to 50% open space volume to total volume of the primary member, wherein the primary member has a first portion distanced from a second portion by a gap, and at least one thermal transfer structure extending between the first portion and the second portion across the gap.

[0007] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure includes at least one of a pin or a fin extending between the first portion and the second portion across the gap.

[0008] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure includes a plurality of the at least one of the pin and the fin extending between the first portion and the second portion across the gap.

[0009] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure has the member porosity.

[0010] Another aspect of the present disclosure includes any of the preceding aspects, further including a braze material infiltration barrier encapsulating a side of the at least one thermal transfer structure, and a center of the at least one thermal transfer structure has the member porosity.

[0011] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure has a thermal transfer (TT) structure porosity different than the member porosity.

[0012] Another aspect of the present disclosure includes any of the preceding aspects, wherein the TT structure porosity is between 2% to 50% open space volume to total volume of the at least one thermal transfer structure.

[0013] Another aspect of the present disclosure includes any of the preceding aspects, further including a braze material infiltration barrier encapsulating a side of the at least one thermal transfer structure, and a center of the at least one thermal transfer structure has the TT structure porosity.

[0014] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure is solid.

[0015] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure is hollow.

[0016] Another aspect of the present disclosure includes any of the preceding aspects, and further includes a cooling passage extending through at least part of the primary member and having a first end open to the gap and a second end extending through an exterior surface of the primary member.

[0017] One aspect of the present disclosure provides a part, the part including a body and an additively manufactured (AM) metal coupon, the AM metal coupon including a primary member having a member porosity between 2% to 50% open space volume to total volume of the primary member. The primary member includes a first portion distanced from a second portion by a gap, at least one thermal transfer structure extending between the first portion and the second portion across the gap, and a braze material coupling the AM metal coupon in a coupon opening in the body, the braze material infiltrated into the primary member based at least on a characteristic of the member porosity.

[0018] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure includes at least one of a pin or a fin extending between the first portion and the second portion across the gap.

[0019] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure includes a plurality of the at least one of the pin and the fin extending between the first portion and the second portion across the gap.

[0020] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure has the member porosity, and the braze material infiltrates at least partially into the at least one thermal transfer structure.

[0021] Another aspect of the present disclosure includes any of the preceding aspects, further including a braze material infiltration barrier encapsulating a side of the at least one thermal transfer structure, a center of the at least one thermal transfer structure has the member porosity, and the braze material infiltrates at least partially into the at least one thermal transfer structure.

[0022] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure has a thermal transfer (TT) structure porosity different than the member porosity.

[0023] Another aspect of the present disclosure includes any of the preceding aspects, wherein the TT structure porosity is between 2% to 50% open space volume to total volume of the at least one thermal transfer structure, and the braze material infiltrates at least partially into the at least one thermal transfer structure based at least on a characteristic of the TT structure porosity.

[0024] Another aspect of the present disclosure includes any of the preceding aspects, further including a braze material infiltration barrier encapsulating a side of the at least one thermal transfer structure.

[0025] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure is solid.

[0026] Another aspect of the present disclosure includes any of the preceding aspects, wherein the at least one thermal transfer structure is hollow.

[0027] Another aspect of the present disclosure includes any of the preceding aspects, and further includes a cooling passage extending through at least part of the primary member and having a first end open to the gap and a second end extending through an exterior surface of the primary member.

[0028] Two or more aspects described in this disclosure, including those described in the Abstract, may be combined to form an embodiment not specifically described herein, i.e., all embodiments described herein may be combined with each other.

[0029] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will become apparent from the description and drawings, and from the claims. [Brief description of the drawings]

[0030] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings illustrating various embodiments of the present disclosure. [Figure 1] 1 illustrates a schematic diagram of an exemplary industrial machine in the form of a gas turbine system and including components according to embodiments of the present disclosure. [Diagram 2] 2 illustrates a cross-sectional view of an exemplary gas turbine assembly that may be used with the gas turbine system of FIG. 1 and includes components according to embodiments of the present disclosure. [Diagram 3] 1 is a perspective view of a component in the form of a turbine rotor blade including a metal coupon according to an embodiment of the present disclosure; [Figure 4]1 is a perspective view of a component in the form of a turbine nozzle including a metal coupon according to an embodiment of the present disclosure; [Diagram 5] FIG. 1 is a schematic block diagram of an exemplary additive manufacturing system for additively manufacturing metal coupons in accordance with an embodiment of the present disclosure. [Figure 6] 1A-1C are top views of sample metal coupons having porous regions with different porosities according to embodiments of the present disclosure. [Figure 7A] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7B] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7C] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7D] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7E] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7F] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7G] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7H] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7I] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7J] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7K] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7L] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7M] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 7N] 1A-1D show various views of a metal coupon according to various embodiments of the present disclosure. [Figure 8A]1 is a perspective view of a method according to various embodiments of the present disclosure. [Figure 8B] 1 is a perspective view of a method according to various embodiments of the present disclosure. [Figure 8C] 1 is a perspective view of a method according to various embodiments of the present disclosure. [Figure 8D] 1 is a perspective view of a method according to various embodiments of the present disclosure. [Figure 8E] 1 is a perspective view of a method according to various embodiments of the present disclosure. [Figure 8F] 1 is a perspective view of a method according to various embodiments of the present disclosure. [Figure 9A] FIG. 13 is an enlarged cross-sectional view of a metal coupon within a coupon opening in a body of a component according to an embodiment of the present disclosure. [Figure 9B] FIG. 13 is an enlarged cross-sectional view of a metal coupon within a coupon opening in a body of a component according to an embodiment of the present disclosure. [Figure 9C] FIG. 13 is an enlarged cross-sectional view of a metal coupon within a coupon opening in a body of a component according to an embodiment of the present disclosure. [Figure 10A] FIG. 1 illustrates an enlarged cross-sectional view of a metal coupon and heat transfer structure(s) at the coupon opening in the body of a part according to an embodiment of the present disclosure. [Figure 10B] FIG. 1 illustrates an enlarged cross-sectional view of a metal coupon and heat transfer structure(s) at the coupon opening in the body of a part according to an embodiment of the present disclosure. [Figure 10C] FIG. 1 illustrates an enlarged cross-sectional view of a metal coupon and heat transfer structure(s) at the coupon opening in the body of a part according to an embodiment of the present disclosure. [Figure 10D] FIG. 1 illustrates an enlarged cross-sectional view of a metal coupon and heat transfer structure(s) at the coupon opening in the body of a part according to an embodiment of the present disclosure. [Figure 10E] FIG. 1 illustrates an enlarged cross-sectional view of a metal coupon and heat transfer structure(s) at the coupon opening in the body of a part according to an embodiment of the present disclosure.

[0031] It should be noted that the drawings of the present disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the present disclosure and therefore should not be considered as limiting the scope of the present disclosure. In the drawings, like numbers represent like elements between the drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] As an initial matter, in order to clearly explain this disclosure, it becomes necessary to select certain terms when referring to and describing relevant machine parts in the exemplary turbomachinery application. In this regard, common industry terms are used, where possible, and are employed in a manner consistent with their common meaning. Unless otherwise specified, such terms should be given a broad interpretation consistent with the context of this application and the scope of the appended claims. Those skilled in the art will appreciate that certain parts are often referred to using several different or overlapping terms. What is described herein as being a single part may include and be referred to as being made up of several parts in other contexts. Alternatively, what is described herein as including several components may be referred to as a single part elsewhere.

[0033] Additionally, several descriptive terms may be used periodically herein, and it may be helpful to define these terms at the beginning of this section. These terms and their definitions are as follows, unless otherwise specified: "downstream" and "upstream" as used herein are terms that indicate a direction relative to the flow of a working fluid or fluid, such as the flow of air through a combustor or the flow of coolant through one of the turbomachine's component systems. The term "downstream" corresponds to the direction of fluid flow, and the term "upstream" refers to the opposite direction to the flow. Additionally, the terms "forward" and "aft" refer to directions, without further specification, with "forward" referring to the forward or compressor end of the turbomachine and "aft" referring to the aft or turbine end of the turbomachine.

[0034] Furthermore, certain descriptive terms may be used regularly herein, as explained below: The terms "first," "second," and "third" may be used interchangeably to distinguish one component from another, and are not intended to imply a position or importance of the individual components.

[0035] The terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It will be further understood that as used herein, the terms "comprises" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. "Optionally" or "optionally" means that the subsequently described event may or may not occur, or the subsequently described feature may or may not be present, and that the description includes instances where the event occurs or the feature is present as well as instances where the event does not occur or the feature is not present.

[0036] When an element or layer is referred to as "resting," "engaged," "connected," "coupled," or "attached" to another element or layer, it may be directly resting, engaged, connected, coupled, or attached to the other element or layer, or there may be intervening elements or layers. In contrast, when an element is referred to as being "directly on," "directly engaged," "directly connected," or "directly coupled" to another element or layer, there are no intervening elements or layers. Other words used to describe relationships between elements should be interpreted similarly (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.). As used herein, the term "and / or" includes any combination of one or more of the associated listed items. In this specification, the verb forms of "coupled" and "mounted" may be used interchangeably.

[0037] As indicated above, the present disclosure provides a part including a body and an additively manufactured (AM) metal coupon including a primary component having a component porosity with an open space volume between 2% and 50% relative to the total volume of the primary component. The primary component has a first portion spaced from a second portion by a gap. At least one heat transfer structure, such as a pin and / or fin, extends across the gap between the first and second portions. A braze material bonds the AM metal coupon within the coupon openings in the body and infiltrates into the primary component based at least on the characteristics of the component's porosity. The braze material may also infiltrate the heat transfer structure(s) that may have the same porosity as the primary component or a different porosity. The porous AM coupon can be made with any type of heat transfer structure that may be filled with one or more braze materials during the braze infiltration step. The heat transfer structure provides improved heat rejection, reduced weight of the component, and improved vibration response of the component. The one or more porosities in the AM metal coupon are configured to direct the flow of one or more braze materials in a different way to create non-traditional physical properties, such as directing more braze material where it is needed, directing the braze material into a special shape, and / or allowing the use of multiple braze materials. When used for repairs, the customized AM metal coupons do not suffer from the same shortcomings as the original parts and / or cutouts, and can be customized (using braze materials) to change, for example, joint adhesive bond strength, coupon strength, stress / strain resistance, ductility, wear resistance, oxidation resistance, cycle fatigue, thermal conductivity, electrical conductivity, surface roughness, hardness, and / or mass.The repair is stronger than traditional narrow gap brazing processes, does not require specific post-repair finishing, and has improved physical properties compared to current technologies such as pre-sintered preforms (PSPs). Bonding the replacement coupon to the part using one or more brazing filler metals also improves joint performance characteristics such as joint bond strength and reliability, and reduces post-braze machining / formulation. The use of porous AM coupons can also reduce material costs, for example, by reducing the amount of expensive base material used in metal coupons.

[0038] FIG. 1 illustrates a schematic diagram of an exemplary industrial machine that may include components according to the teachings of the present disclosure. In this example, the machine includes a turbomachine 100 in the form of a combustion or gas turbine (GT) system. The turbomachine 100 includes a compressor 102 and a combustor 104. The combustor 104 includes a combustion region 106 and a fuel nozzle assembly 108. The turbomachine 100 also includes a turbine assembly 110 and a common compressor / turbine shaft or rotor 112. In one embodiment, the turbomachine 100 is a 7HA.03 engine commercially available from GE Vernova. The present disclosure is not limited to any particular GT system and may be implemented in connection with other engines including, for example, other HA, F, B, LM, GT, TM and E class engine models from GE Vernova, as well as engine models from other manufacturers. Additionally, the present disclosure is not limited to a particular turbomachine and may be applicable to, for example, steam turbines, jet engines, compressors, turbofans, and the like. Additionally, the present disclosure is not limited to a particular turbomachine part and may be applicable to any industrial part that uses coupons during manufacture or repair.

[0039] In operation, air flows through the compressor 102 and the compressed air is delivered to the combustor 104. Specifically, the compressed air is delivered to a fuel nozzle assembly 108 that is integral with the combustor 104. The assembly 108 is in flow communication with the combustion region 106. The fuel nozzle assembly 108 is also in flow communication with a fuel source (not shown in FIG. 1 ) and channels fuel and air to the combustion region 106. The combustor 104 ignites and burns the fuel. The combustor 104 is in flow communication with a turbine assembly 110 in which thermal energy of the gas stream is converted to mechanical rotational energy. The turbine assembly 110 includes a turbine 111 that is rotatably coupled to and drives a rotor 112. The compressor 102 is also rotatably coupled to the rotor 112. In the illustrated embodiment, there are multiple combustor and fuel nozzle assemblies 108.

[0040] FIG 2 illustrates a cross-sectional view of an exemplary turbine assembly 110 of turbomachine 100 (FIG. 1) that may be used with the gas turbine system of FIG. 1. A turbine 111 of turbine assembly 110 is coupled to a stationary casing 122 of turbomachine 100 and includes a row of nozzles or vanes 120 axially adjacent a row 124 of rotating blades 132. The stationary vanes or nozzles 126 may be retained in turbine assembly 110 by a radially outer platform 128 and a radially inner platform 130. The blade row 124 of turbine assembly 110 includes rotating blades 132 that are coupled to rotor 112 and rotate therewith. The rotating blades 132 may include a radially inner platform 148 (blade root, FIG. 3) that is coupled to rotor 112 and optionally a radially outer tip shroud 136 (blade tip). As used herein, the term "component" may collectively refer to the stationary nozzle 126, the rotating blades 132, or any other structure in which a metal coupon including a porous region according to the present disclosure may be employed.

[0041] 3 and 4 illustrate example components, such as hot gas path components of turbomachinery, in which teachings of the present disclosure may be employed. FIG. 3 illustrates a perspective view of a turbine rotor blade 132 of a type in which embodiments of the present disclosure may be employed. The turbine blade 132 includes a root 140 at which the blade 132 is attached to the rotor 112 (FIG. 2). The root 140 may include a dovetail 142 configured to attach to a corresponding dovetail slot in an outer periphery of a rotor wheel 144 (FIG. 2) of the rotor 112 (FIG. 2). The root 140 may further include a shank 146 extending between the dovetail 142 and a platform 148 disposed at the junction of the airfoil 150 and the root 140, the platform 148 defining a portion of an inboard boundary of a flowpath through the turbine assembly 110. It will be appreciated that the airfoil 150 is an active component of the rotor blade 132 that intercepts the flow of working fluid 151 (FIG. 2), i.e., hot combustion gases, and directs the rotor disk to rotate. It will be seen that the airfoil 150 of the rotor blade 132 includes a concave pressure side (PS) outer wall 152 and circumferentially or laterally opposed convex suction side (SS) outer walls 154 that extend axially between opposed leading and trailing edges 156, 158, respectively. The side outer walls 152, 154 also extend radially from the platform 148 to an outboard tip 160, which may or may not include a tip shroud 136 (FIG. 2).

[0042] 4 illustrates a perspective view of a static nozzle 126 in which an embodiment of the present disclosure may be employed. The static nozzle 126 includes an outer platform 170 to which the static nozzle 126 mounts to a stationary casing 122 (FIG. 2) of a turbomachine. The outer platform 170 may include any now known or later developed mounting configuration for mounting to a corresponding mount in the casing. The static nozzle 126 may further include an inner platform 174 for positioning between an adjacent turbine rotor blade 132 (FIG. 3) and the platform 148 (FIG. 3). The platforms 170, 174 define respective portions of the outboard and inboard boundaries of the flowpath through the turbine assembly 110. It will be appreciated that the airfoil 176 is an active component of the static nozzle 126 that intercepts and directs the flow of the working fluid toward the turbine rotor blades 132 (FIG. 3). It will be seen that the airfoil 176 of the static nozzle 126 includes a concave pressure side (PS) outer wall 178 and circumferentially or laterally opposed convex suction side (SS) outer walls 180 extending axially between opposing leading and trailing edges 182, 184, respectively. The side outer walls 178, 180 also extend radially from platform 170 to platform 174.

[0043] It is understood that the blades 132 or nozzles 126 may include internal cooling structures including a source of coolant, such as passages, conduits, and other structures that supply coolant to their surfaces for film cooling. The coolant may include air from the compressor 102, for example.

[0044] The disclosed embodiments described herein may include aspects applicable to either the static nozzle 126, the turbine rotor blade 132, and / or any other industrial part employing a coupon. Figures 3 and 4 also show an exemplary additive manufacturing (AM) metal coupon 200 (hereinafter "metal coupon 200" or "AM metal coupon 200" for brevity) in a part 202. More specifically, the metal coupon 200 may be in a coupon opening 204 in a body 206 of the part 202. The "coupon opening 204 in body 206" may be any size void in the body 206 up to and including a removed portion of the body 206, such as a tip shroud. For example, the metal coupon 200 may be in the coupon opening 204 in the trailing edge 158, 184 of the blade 132 or the nozzle 126, respectively. Alternatively, the metal coupon 200 can be in a coupon opening 204 in the leading edge 156, 182 of the blade 132 or nozzle 126, respectively. The metal coupon 200 can also be in any tip (not shown) of the blade 132 or platform 170 (shown in FIG. 4), 174 of the nozzle 126. However, it is emphasized that the metal coupon 200 can be employed in any coupon opening 204 in the body 206 of the part 202. The body 206 can be any portion or all of the part 202.

[0045] The additively manufactured metal coupon 200 includes one or more porous regions therein and can be additively manufactured using any now known or later developed technique capable of forming the porous regions. FIG. 5 is a schematic / block diagram of an exemplary computerized metal powder additive manufacturing system 210 (hereinafter "AM system 210") for generating a metal coupon 200 or multiple metal coupons 200A, 200B, of which only a single layer is shown. It will be emphasized and readily appreciated that the teachings of the present disclosure are similarly applicable to constructing multiple coupons 200A, 200B using any number of melt beam sources, although the teachings of the present disclosure are described in connection with constructing a metal coupon 200 using multiple melt beam sources 212, 214, 216, 218. In this example, the AM system 210 is configured for direct metal laser melting (DMLM). It is understood that the general teachings of the present disclosure are equally applicable to other forms of metal powder additive manufacturing, such as powder bed fusion, direct metal laser sintering (DMLS), electron beam melting (EBM), selective laser sintering (SLS), selective laser melting (SLM), and perhaps other forms of additive manufacturing (ie, other than metal powder applications). Although the coupons 200A, 200B are illustrated as rectangular elements, it is understood that the additive manufacturing process can be readily adapted to produce coupons of any shape, a wide variety of different coupons, and a large number of coupons on the build platform 220.

[0046] The AM system 210 generally includes an additive manufacturing control system 230 ("control system") and an AM printer 232. As will be described, the control system 230 executes a set of computer executable instructions or code 234 to generate the coupon 200 using multiple melt beam sources 212, 214, 216, 218. In the illustrated example, the four melt beam sources may include four lasers. However, the teachings of the present disclosure are applicable to any melt beam source, e.g., electron beam, laser, etc. The control system 230 is shown embodied on a computer 236 as computer program code. To this extent, the computer 236 is shown including a memory 238 and / or storage system 240, a processor unit (PU) 244, an input / output (I / O) interface 246, and a bus 248. Additionally, the computer 236 is shown in communication with an external I / O device / resource 250. Generally, the processor unit (PU) 244 executes computer program code 234 stored in memory 238 and / or storage system 240. The computer program code may read and / or write data to memory 238, storage system 240, I / O device 250, and / or AM printer 232. Bus 248 provides a communication link between each component in computer 236, and I / O device 250 may consist of any device that allows a user to interact with computer 236 (e.g., keyboard, pointing device, display, etc.). Computer 236 is merely representative of various possible combinations of hardware and software. For example, processor unit (PU) 244 may consist of a single processing unit or may be distributed across one or more processing units on one or more locations, e.g., a client and a server. Similarly, memory 238 and / or storage system 240 may reside in one or more physical locations.Memory 238 and / or storage system 240 may be comprised of any combination of various types of non-transitory computer-readable storage media including magnetic media, optical media, random access memory (RAM), read-only memory (ROM), etc. Computer 236 may comprise any type of computing device, such as an industrial controller, a network server, a desktop computer, a laptop, a handheld device, etc.

[0047] As previously discussed, the AM system 210, and in particular the control system 230, executes the code 234 to generate the metal coupon(s) 200. The code 234 may include, among other things, a set of computer-executable instructions 234S (also referred to herein as “code 234S”) for operating the AM printer 232, and a set of computer-executable instructions 234O (also referred to herein as “code 234O”) that define the metal coupon(s) 200 that are physically generated by the AM printer 232. As described herein, the additive manufacturing process begins with a non-transitory computer-readable storage medium (e.g., memory 238, storage system 240, etc.) that stores the code 234. The set of computer-executable instructions 234S for operating the AM printer 232 may include any now known or later developed software code capable of operating the AM printer 232.

[0048] The set of computer executable instructions 234O defining the metal coupon(s) 200 may include a precisely defined 3D model of the coupon and may be generated from any of a wide variety of well-known computer-aided design (CAD) software systems, such as AutoCAD®, TurboCAD®, DesignCAD 3D Max, etc. In this regard, the code 234O may include any file format now known or later developed. Additionally, the code 234O representative of the metal coupon(s) 200 may be converted between different formats. For example, the code 234O may include a Standard Tessellation Language (STL) file created for 3D Systems' stereolithography CAD program, or an Additive Manufacturing File (AMF), an American Society of Mechanical Engineers (ASME) standard that is an Extensible Markup Language (XML)-based format designed to allow any CAD software to describe the shape and configuration of any three-dimensional object to be manufactured by any AM printer. The code 234O representing the metal coupon(s) 200 may also be converted to a set of data signals and transmitted, received as a set of data signals and converted to code, stored, etc., as desired. The code 234O may be configured to enable the formation of boundaries and interior sections in overlapping field regions, as will now be described, in accordance with embodiments of the present disclosure. In either case, the code 234O may be an input to the AM system 210 and may come from a part designer, an intellectual property (IP) provider, a design firm, an operator or owner of the AM system 210, or other source. In either case, the control system 230 executes the codes 234S and 234O to divide the metal coupon(s) 200 into a series of slices that are assembled with successive layers of material using the AM printer 232.

[0049] The AM printer 232 may include a process chamber 260 sealed to provide a controlled atmosphere for printing of the metal coupon(s) 200. A build platform 220 on which the metal coupon 200 is / is built is disposed within the process chamber 260. Multiple melt beam sources 212, 214, 216, 218 are configured to melt a layer of metal powder on the build platform 220 to generate the coupon 200. Although four melt beam sources 212, 214, 216, 218 are illustrated, it is emphasized that the teachings of the present disclosure are applicable to systems employing any number of sources, e.g., one, two, three, or five or more. As will be understood in the art, each melt beam source 212, 214, 216, 218 may each have a field that includes a non-overlapping field region where it is exclusively capable of melting metal powder, and may include at least one overlapping field region where two or more sources are capable of melting metal powder. In this regard, each melt beam source 212, 214, 216, 218 may generate a melt beam that melts the particles for each slice, as defined by reference numeral 234O. For example, in FIG. 5, melt beam source 212 is shown forming a layer of metal coupon(s) 200 using melt beam 262 in one area, while melt beam source 214 is shown forming a layer of metal coupon(s) 200 using melt beam 262′ in another area. Each melt beam source 212, 214, 216, 218 is calibrated in any manner now known or later developed. That is, each melt beam source 212, 214, 216, 218 has the expected position of its laser or electron beam relative to the build platform 220 correlated with the actual position to provide individual position corrections (not shown) to ensure its individual accuracy. In one embodiment, each of the multiple melt beam sources 212, 214, 216, 218 can generate a melt beam, eg, 262, 262', having the same cross-sectional dimensions (eg, operational shape and size), power, and scan speed.

[0050] Continuing with FIG. 5, the applicator (or re-coater blade) 270 can create a thin layer of feedstock 272 that is laid down as a blank canvas from which each successive slice of the final coupon is created. Various parts of the AM printer 232 can move to accommodate the addition of each new layer, for example, the build platform 220 can be lowered after each layer, and / or the chamber 260 and / or the applicator 270 can be raised. The process can use different raw materials in the form of fine metal powders, which can be kept in a stock in the chamber 260 accessible by the applicator 270. In the instant case, the coupon(s) 200 can be made of metals, including pure metals or alloys. In one example, the metal can include virtually any non-reactive metal powder, i.e., non-explosive or non-conductive powder, such as cobalt chromium molybdenum (CoCrMo) alloy, stainless steel, austenitic nickel-chromium based alloys such as nickel-chromium-molybdenum-niobium alloy (NiCrMoNb) (e.g., but not limited to, Inconel 625 or Inconel 718), nickel-chromium-iron-molybdenum alloy (NiCrFeMo) (e.g., Hastelloy® X available from Haynes International, Inc.), or nickel-chromium-cobalt-molybdenum alloy (NiCrCoMo) (e.g., Haynes 282 available from Haynes International, Inc.). Other possibilities include, for example, Rene 108, CM 247 LC, Mar M 247, and any precipitation harden-able (PH) nickel alloy.

[0051] The process chamber 260 is filled with an inert gas, such as argon or nitrogen, and is controlled to minimize or eliminate oxygen. The control system 230 is configured to control the flow of the gas mixture 274 in the process chamber 260 from an inert gas source 276. In this case, the control system 230 can control a pump 280 and / or a flow valve system 282 for the inert gas to control the content of the gas mixture 274. The flow valve system 282 can include one or more computer-controllable valves, flow sensors, temperature sensors, pressure sensors, etc., that can precisely control the flow of a particular gas. The pump 280 can be provided with or without the valve system 282. If the pump 280 is omitted, the inert gas can simply enter a conduit or manifold before being introduced into the process chamber 260. The source 276 of the inert gas can take the form of any conventional source for the material contained therein, such as a tank, reservoir, or other source. Any sensors (not shown) required to measure the gas mixture 274 can be provided. The gas mixture 274 may be filtered using a filter 286 in a conventional manner.

[0052] In operation, the build platform 220 having metal powder thereon is provided within the process chamber 260, and the control system 230 controls the flow of a gas mixture 274 within the process chamber 260 from an inert gas source 276. The control system 230 also controls the AM printer 232, particularly the applicator 270 and the melt beam sources 212, 214, 216, 218, to sequentially melt layers of metal powder on the build platform 220 to generate a metal coupon 200 in accordance with an embodiment of the present disclosure.

[0053] While a particular AM system 210 is described herein, it is emphasized that the teachings of the present disclosure are not limited to a particular additive manufacturing system or method. Also, while the teachings of the present disclosure relate to additively manufactured metal coupon(s) 200, it will be recognized that part 202 may be manufactured by any method now known or later developed, such as additive manufacturing (perhaps similar to that described for metal coupon(s) 200), casting, or other methodologies. Part 202 may include any of the materials described herein for metal coupon 200.

[0054] 7A-D show perspective views, FIG. 7E shows a side view, and FIG. 7F shows a top view of an exemplary AM metal coupon 200 for insertion into a part 202. The metal coupon 200 includes an AM primary member 290 and has a member porosity of between 2% and 50% relative to the total volume of the primary member. More specifically, the primary member 290 has one or more porous regions 300 (having holes 302). (As used herein, "member porosity" refers generally and collectively to the porosity or porosities of the primary members 290, which may be a single porosity or many different porosities depending on the arrangement of porous regions therein, as will be explained. When a distinction is required between different member porosities, the terms "first member porosity" or "second member porosity" or "member variable porosity" are used, as appropriate.)

[0055] 7A shows a metal coupon 200 having a single porous region 300 of a first member porosity (the entire metal coupon 200 has the first member porosity), FIG. 7B shows a metal coupon 200 having one or more porous regions 300A-B having different porosities within the described range, FIG. 7C shows a metal coupon 200 having one or more porous regions 300A-B having different porosities within the described range and a solid region 304, and FIG. 7D shows a metal coupon 200 having a variable porosity region 300D within the described range between (and possibly including) the first porous region 300A and the second porous region 300B. The primary member 290 also has a first portion 330 spaced from a second portion 332 by a gap 334. The metal coupon 200 also includes at least one heat transfer structure 340 extending between the first portion 330 and the second portion 332 across the gap 334. The gaps 334 are open spaces or voids formed where the metal coupon 200 would normally be solid material, and thus represent material removed to provide space for the heat transfer structures 340 (hereinafter, for brevity, "TT structure(s)" or "TT structures 340").

[0056] The metal coupon 200 in Figures 7A-F is shown having a shape configured to be placed in a coupon opening 204 in the trailing edge 158 or 184 of the blade 132 or nozzle 126, respectively, or in a coupon opening 204 in the leading edge 156 or 182 of the blade 132 or nozzle 126, respectively, as shown in Figures 3, 4, and 8B-F. The metal coupon 200 may also be at any tip (not shown) of the platform 170, 174 (Figure 4) of the blade 132 or nozzle 126. However, it is emphasized that the metal coupon 200 may be employed in any coupon opening 204 in any portion of the body 206 of any part 202.

[0057] "Porosity," as used herein, is the ratio of the volume of open space to the total volume of the described structure, e.g., porous region, TT structure, metal coupon, etc. Typically, in this regard, porosity is described as the percentage of the volume of open space to the entire or total volume of the described structure. Open space in terms of porosity is empty area in a solid material, sometimes referred to herein as "pores" 302, and may include interconnected passages in the material of the described structure. A "porous area" in the metal coupon 200 is thus less than 100% solid (100% solid corresponds to 0% porosity) and includes empty space in the form of pores 302 and / or interconnected passages. The porous metal coupon 200 may include solid areas, but also includes one or more porous areas that are less than 100% solid. As previously mentioned, the porous metal coupon 200 may also include gaps 334, i.e., gaps 334 having 100% porosity. The gaps 334 are significantly larger than any open space in the porous region 300 of the primary component 290. As used herein, the three-dimensional boundaries of a porous region or subregion for purposes of identifying its "total volume" may be identified by locations within the metal coupon 200 and / or within the edges of the metal coupon 200 where a change in porosity of more than 2% occurs relative to adjacent regions or subregions. "Open space volume" collectively refers to three-dimensional space within a region or subregion that is empty, i.e., a void, gap, empty space and / or not filled with material (not including the gaps 334).As used herein, "different porosities" or "differences in porosity" generally refers to any of a variety of characteristics, such as the ratio of open space volume to total volume, the number of pores 302 in a given volume, the volume (i.e., size) of the pores 302, the shape of the pores 302, and variations in the communication passages between the pores 302 (referred to herein as "pore connecting passages") that may not be recognized as actual individual pores. As one non-limiting example only, pore size may vary from, for example, 1.07x10. -6 ~8.58x10 -3 cubic millimeter (6.54x10 -11 ~5.24x10 -7 cubic inches), or, as another non-limiting example, pore diameters can range from 0.0127 millimeters (mm) to 0.254 millimeters (0.0005 inches to 0.01 inches). In the drawings, the different porous regions or sub-regions are typically shown as being continuous or in contact with one another, however, it is emphasized that they may be separated from one another in any manner, e.g., with solid regions therebetween. That is, a single metal coupon may include one or more separate, non-contacting porous regions or sub-regions. It is noted that the terms "region" and / or "sub-region" may be used interchangeably to describe variations in porosity. It will be appreciated that differences in porosity are not based solely on the ratio of open space volume to total volume, e.g., due to differences in pore shapes or pore interconnections. However, when differences in porosity are compared in terms of degree, e.g. high or low, the difference referred to is exclusively a volumetric property, i.e. the percentage of open space volume to total volume.

[0058] One or more porous metal coupons 200 can be formed with porous regions of differing porosity (which may or may not include one or more porous sub-regions of differing porosity) using the AM system 210 described herein or any other metal additive manufacturing system or method capable of forming porous metal. With respect to the operation of the AM system 210, the melting beam sources 212, 214, 216, 218 can be programmed to intermittently not sinter the metal, leaving metal powder rather than solidified (sintered) metal powder material. This process can include overlapping the laser field areas by different amounts and / or designing the holes 302 in the build file, i.e., code 234O. Less overlap of each laser scan results in higher porosity, while more laser overlap between successive scans results in lower porosity. The laser spot size, scan speed, focus and / or power can also be controlled to adjust the porosity. More specifically, additive manufacturing involves using an AM system 210 having one or more melt beam sources 212, 214, 216, 218 to fuse layers of metal powder together and adjusting parameters of the system to control the porosity of at least two porous regions. Adjusting the parameters may include at least one of adjusting the amount of overlap of the melt regions of one or more melt beams 262, 262' (FIG. 5) (from the sources 212, 214, 216, 218), adjusting the scanning speed of the system, or adjusting at least one of the spot size, focus, and / or power of the melt beams. When the unmelted metal powder is removed from the metal coupon 200, it leaves behind holes 302 with interconnected passages between the holes 302, forming one or more porous regions in the metal coupon 200. In any case, the layered manufacturing of the metal coupon 200 can be controlled to form any number, shape, and / or size of porous regions in any desired layer of the metal coupon 200.

[0059] 6A-D are top schematic diagrams of sample metal coupons 200 with different porosities. The holes 302 are shown in the figures as dark open spaces. FIG. 6A shows the sample metal coupon 200 with a first porosity of about 40% open pore volume relative to the total volume of the sample (generally more open pore volume, more or larger holes 302), FIG. 6B shows the sample metal coupon 200 with a first porosity of about 30% open pore volume relative to the total volume of the sample, FIG. 6C shows the sample metal coupon 200 with a first porosity of about 20% open pore volume relative to the total volume of the sample, and FIG. 6D shows the sample metal coupon 200 with a first porosity of about 10% open pore volume relative to the total volume of the sample (generally less amount of open pores). Each porous region can have an open space volume of 2%-50% relative to the total volume of the porous region, i.e., a porosity between 2%-50% open space and the remaining 50%-98% solid. In other embodiments, each porosity may be between 10% and 40% open space volume with another 60% to 90% density relative to the total volume of the porous regions 300. In other embodiments, the porous regions may be provided on the metal coupon 200 with porosities in the range of less than 10%, less than 15%, less than 20%, less than 25%, less than 30%, less than 35%, less than 40%, less than 45%, 2% to 45%, 2% to 40%, 2% to 35%, 2% to 30%, 2% to 25%, 2% to 20%, 5% to 45%, 5% to 40%, 5% to 35%, 5% to 30%, 5% to 25%, 5% to 50 ... porosity may range from 10% to 20%, 10% to 45%, 10% to 40%, 10% to 35%, 10% to 30%, 10% to 25%, 10% to 20%, 15% to 45%, 15% to 40%, 15% to 35%, 15% to 30%, 15% to 25%, 15% to 20%, 10% to 50%, 20% to 50%, 25% to 50%, 30% to 50%, 35% to 50%, or 40% to 50%. Other ranges of porosity are possible as described herein.

[0060] As shown in FIG. 7A, the metal coupon 200 can have a first porous region 300 with a first member porosity. In FIG. 7A, the metal coupon 200 includes a single porous region 300 with a single first member porosity. In FIG. 7A, the entire metal coupon 200 includes the first member porosity. Thus, each layer of the metal coupon 200 has the same porosity. In FIG. 7B, the metal coupon 200 includes two porous regions 300A-B, each with a different porosity. Here, the regions defining the regions 300A-B within the layer of the metal coupon 200 can be formed to include holes 302. In FIG. 7C, the metal coupon 200 includes one or more porous regions 300C, each possibly with the same or different porosity, and a solid region 304. Here, the regions in the layer of the metal coupon 200 that define the regions 300A-B or 300C may be formed to include holes 302, and the regions in the layer of the metal coupon 200 that define the solid region 304 are formed without holes 302. Although not necessary in all cases, the porous region 300C can be located in the first and second portions 330, 332 of the primary member 290 separated by a gap 334. In this arrangement, the brazing material 310 (FIGS. 9A-C) can infiltrate the TT structure 340, which is also porous, as will be further described. In FIG. 7D, the metal coupon 200 includes a variable porosity region 300D between (and possibly including a portion of) the first porous region 300A and the second porous region 300B. Here, regions 300A-B or regions within the layer of metal coupon 200 defining variable porosity region 300D may be formed to include, for example, different sizes and / or numbers of holes 302, resulting in different porosities. Variable porosity region 300D may have any porosity that varies, for example, increases, decreases, and / or has both increases and decreases. The change in porosity may be gradual, stepped, or otherwise incremental. Each porous region 300 may have an open space volume of 2%-50% relative to the total volume of the porous region 300, i.e., a porosity between 2%-50% open space and the remaining 50%-98% dense. In other embodiments, each porosity may be in any range as described herein.

[0061] The one or more TT structures 340 can take a variety of forms. Figures 7G and 7N show side views and Figures 7H-L and 7M show top views of various alternative arrangements of the one or more TT structures 340 on the metal coupon 200. As shown in Figures 7A-M, the one or more TT structures 340 can include at least one of a pin 342 and / or a fin 344 extending across the gap 334 between the first portion 330 and the second portion 332. In certain embodiments, the one or more TT structures 340 include one or more pins 342 and / or one or more fins 344 extending across the gap 334 between the first portion 330 and the second portion 332. Figures 7A-F show an embodiment having multiple pins 342, Figures 7H-J show a single pin 342, Figure 7K shows multiple fins 344, and Figures 7L-M show multiple pins 342 and fins 344. 7G and 7N show a side view of one or more TT structure(s) 340. The pins 342 have a generally uniform cross-sectional dimension and may have cross-sectional shapes such as, but not limited to, circular, square, and / or polygonal (e.g., pentagonal, octagonal, etc.). In contrast, as shown in FIGS. 7K-M, the fins 344 may have some elongated dimension along at least one direction of the fin and may have cross-sectional shapes such as, but not limited to, oval, elliptical, football-shaped, airfoil, etc.

[0062] The pins 342 and fins 344 may also include exterior features to enhance cooling. To further enhance convective cooling, cooling may be enhanced by bumps, ribs, dimples (hereinafter generally referred to as turbulators) formed on the exterior surfaces of the pins 342 and fins 344. As used herein, a "turbulator" may be any feature or structure disposed on the surface of the pins 342 and fins 344 in a fluid passage and configured to disturb, agitate, or otherwise affect the flow of fluid in that passage. The turbulators may be formed in any suitable size, number, spacing, shape, and orientation. The turbulators may have any suitable cross-sectional shape. For example, the turbulators may have a circular, non-circular, elliptical, oblong, irregular, rectangular, or any other cross-sectional shape suitable for a particular heat exchange fluid flow. Other turbulator configurations are considered within the scope of the presently described embodiments.

[0063] The one or more TT structures 340, e.g., the one or more pins 342 and / or the one or more fins 344, may be arranged in any desired manner, e.g., to provide sufficient structural support, heat removal, and / or coolant flow direction. For example, as shown in the non-limiting embodiment of Figures 7A-F, the pins 342 may be arranged in rows or staggered. In another non-limiting example, as shown in Figures 7K-L, the pins 342 and fins 344 are arranged together in one or more rows. Other arrangements are possible.

[0064] The one or more TT structures 340 may have a variety of physical forms. As shown in Figures 7B, 7E-7I, the one or more TT structures 340 may be solid (solid / dense), i.e., 0% porosity. In other embodiments, as shown in Figure 7M, the one or more TT structures 340 may be hollow, i.e., have an outer layer(s) that are 0% porosity and a hollow center 380 that is open space (100% porosity). Alternatively, in Figures 7A, 7C-D, and 7J, the TT structure(s) 340 are at least partially porous. In certain embodiments, as shown in Figures 7A and 7C, the TT structure(s) 340 may have a TT structure porosity that is the same as any member porosity of the primary member 290, or at least the same as its first and second portions 330, 332 (Figure 7C), for example, the primary member 290 generally includes a single porosity. In other embodiments, as shown in Figures 7B, 7D, and 7J, the TT structure(s) 340 may have a TT structure porosity that is different from any member porosity of the primary member 290, or at least the member porosity of the first and second portions 330, 332 of the primary member 290 adjacent to the TT structure(s) 340. The TT structure porosity may be between 2% and 50% open space volume relative to the total volume of the respective TT structure 340. In alternative embodiments, the TT structure porosity may be any of the other ranges described herein for member porosity.

[0065] As shown in FIG. 7J, regardless of whether the TT structure(s) 340 have a member porosity or a different TT structure porosity, in certain embodiments, the braze infiltration barrier 350 can encapsulate the sides of the TT structure(s) 340. When the TT structure 340 has a member porosity, the center 352 of the TT structure(s) has the same porosity as the member porosity, i.e., the porosity inside the barrier 350. That is, the center 352 of the TT structure(s) has a member porosity. In contrast, when the TT structure 340 has a different TT structure porosity, the center 352 of the TT structure(s) has the TT structure porosity, i.e., the porosity inside the barrier 350. In either case, the porous portion of the TT structure 340 is inside the barrier 350. The barrier 350 may comprise a material with low porosity, e.g., molten metal powder, that is impermeable to the braze material 310 (FIGS. 8E-F, 9A-C) used to bond the metal coupon 200 to the coupon opening 204 of the body 206 of the part 202. That is, the barrier 350 has a low enough porosity to act as a braze material flow blocker and / or containment layer for the porous center 352 of the TT structure(s) 340. The barrier 350 may be relatively thin, e.g., less than 0.5 millimeters. The porosity of the barrier 350 prevents the ingress and / or penetration of the braze material 310 (FIGS. 9A-C) and may vary depending on the material of the metal coupon 200 and the material of the braze material 310. That is, the barrier 350 allows some lateral ingress of the braze material 310 but does not allow the braze material 310 to pass through the outer surface of the TT structure(s) 340. Longitudinally, the braze material 310 may at least partially penetrate the TT structure 340 based at least on its porosity characteristics. Although not required, the barrier 350 may be 100% solid, i.e., 0% open space. As described further herein, the braze material 310 directed to penetrate the porous centers 352 will penetrate until it reaches the barrier 350. Thus, the barrier 350 may define a lateral limit for the penetration of the braze material 310 into each porous center 352.In any embodiment, as shown in the side view of FIG. 7N, the porous center 352 of the TT structure(s) 340 may be selectively blocked from porous-fluid communication with the porous first portion 330 or second portion 332 of the primary member 290. In this case, an end barrier 354 or 356 (outlined in white), having a porosity similar to that of the barrier 350, may block porous-fluid communication between the porous center 352 of the TT structure(s) 340 and selective one of the first portion 330 or second portion 332 of the primary member 290. The braze material 310 that infiltrates the porous center 352 of each TT structure 340 may be the same or different than that used elsewhere in the primary member 290, depending, for example, on whether the respective porous center 352 is in porous-fluid communication (open) with the first portion 330 and / or second portion 332 of the primary member 290 and the brazing process used. The porosity of the first and / or second portions 330, 332, the type of brazing material 310 used, among other factors, may also affect what brazing material 310 is present in each porous center 352 of one or more TT structures 340.

[0066] 7A-B, 7E-J, the metal coupon 200 may optionally include one or more cooling passages 360 that extend through at least a portion of the primary member 290 and have a first end 362 (FIG. 7E) that is open to the gap 334 and a second end 364 that extends through the exterior surface 308 of the primary member 290. In most cases, the cooling passages 360 are shown having a straight path, but may extend in any manner, such as a serpentine path through the metal coupon 200 or extending through the exterior surface 308 of the metal coupon 200.

[0067] 3-5, 7A-N, and 8A-F, an embodiment of a method according to the present disclosure will now be described. The method may include, for example, inserting a metal coupon 200 into a part 202 to repair or build the part 202. Figures 8A-F are perspective views of a method according to an embodiment of the present disclosure.

[0068] FIG. 8A illustrates forming a coupon opening 204 in the body 206 of the part 202. The coupon opening 204 is configured to receive the metal coupon 200. The coupon opening 204 can have any shape desired. In certain applications, the coupon opening 204 is created by removing a damaged portion of the body 206 of the part 202, but the coupon opening 204 can also be located in a portion of the original version of the part 202, such as in a location that would be difficult to manufacture with the remainder of the part 202. In the non-limiting example shown, the coupon opening 204 is at the trailing edge 184 of the nozzle 126. FIG. 8A also illustrates creating a model of the coupon opening 204. Creating the model can include scanning and creating a digitized representation of the coupon opening 204 relative to the body 206 of the part 202 using any now known or later developed three-dimensional scanner (not shown, see arrow). The process of scanning and modeling a part is well known in the art and further details will be omitted to allow the reader to focus on the salient aspects of the present disclosure.

[0069] 5, 7A-N illustrate an additively manufactured metal coupon 200 as described herein. Additive manufacturing may include any of the AM processes described herein for manufacturing a porous metal coupon 200 (or dense or solid regions). Additive manufacturing may include selectively forming porous region(s), such as the region(s) 300 of the primary member 290 and / or the porous regions of the TT structure(s) 340, by controlling the AM printer 232. Additive manufacturing may include manufacturing the metal coupon 200 to generally match the profile (e.g., shape, dimensions, etc.) of the coupon opening 204 or to have a near net shape of the coupon opening 204 based on a model of the coupon opening 204. As used herein, "near net shape" indicates that the metal coupon 200 is within desired manufacturing tolerances with no or minimal additional processing, such as machining, at a specified stage of the manufacturing process. Some additional texturing or polishing to the exterior surface may be desired. Once the metal coupon 200 is attached to the part, additional coatings may be applied. When formed to near net shape, the metal coupon 200 may also have an as-manufactured shape when placed in the coupon opening 204 that closely approximates the surface(s) of the body 206 required to bond the metal coupon 200 to the coupon opening 204, for example, with the selected braze material(s) and no or minimal finishing methods such as machining or grinding. The use of a porous region 300 in the primary member 290 of the metal coupon 200 can accommodate a larger variation in bond gap dimensions because the porous region provides improved grasp and hold of the braze material despite the large gap compared to a solid coupon with a narrow gap for the braze material. The metal coupon 200 is shown additively manufactured as the embodiment of FIG. 7B in FIGS. 8B-C, but may take any form described throughout this disclosure.

[0070] In accordance with an embodiment of the present disclosure, the porosity of one or more porous regions in the metal coupon 200 is controlled, i.e., customized, to control the flow of brazing material therein during a subsequent brazing process that bonds the metal coupon(s) 200 to the coupon openings 204 in the body 206 of the part 202, as shown in Figures 3, 4, and 9A-C. Each porous region can be customized with respect to any of the aforementioned characteristics that affect porosity. In addition, the shape and / or location of the porous regions 300 of the primary member 290 can be arranged to direct the brazing material as desired. For example, in Figure 7A, the entire metal coupon 200 includes the first porous region 300, so that the brazing material 310 is uniformly distributed therein. In contrast, in FIG. 7B, the metal coupon 200 includes one porous region 300A near an edge 306 of the metal coupon 200 that will mate with the coupon opening 204 (FIGS. 3-4), and a different porous region 300B having a different porosity adjacent to the first porous region 300A, e.g., distal from the edge 306. In this manner, the brazing material 310 is distributed in a different manner in each porous region 300, resulting in different physical property(ies) in different regions of the metal coupon 200. More specifically, any number of porous regions 300 can be used to customize (create) at least one physical property in the part 202 including the metal coupon 200, e.g., bond bond strength, coupon strength, stress / strain resistance, ductility, wear resistance, oxidation resistance, cyclic fatigue, thermal conductivity, electrical conductivity, surface roughness, hardness, and / or mass. In a non-exhaustive list of possibilities, the metal coupon 200 can include a high porosity in one region 300 to direct more brazing material thereto by capillary action as compared to other regions of the metal coupon 200 to control at least one physical property of the part 202. In another embodiment, the metal coupon 200 can include a lower porosity in one region 300 to direct less brazing material thereto by capillary action as compared to other regions of the metal coupon 200 to control at least one physical property of the part 202.In other embodiments, the metal coupon 200 may include two or more porous regions 300 that collectively make up the entirety of the metal coupon 200. As will be appreciated, the brazing material 310 may also be directed to the TT structure(s) 340 based on their porosity. The porous regions of the primary member 290 and / or TT structure 340 may be in any arrangement to create the desired brazing material flow and infiltration. Any arrangement of the TT structure(s) 340 may be used. In particular, any mixture of solid, hollow and / or porous TT structures 340 may be used.

[0071] In certain embodiments, additive manufacturing can also include forming any of a variety of improvements for the part 202 in the metal coupon 200, including, for example, structures not previously present in the part 202. The part 202 can be the original part in need of improvement or a part that includes a removed or damaged part. For example, additive manufacturing can add TT structures 340 not previously present in the part 202. Additionally, additive manufacturing can optionally include forming cooling passages 360 in the metal coupon 200. Any advantageous internal structural modifications can be made to the metal coupon 200. Post-additive manufacturing finishing processes now known or later developed can optionally be performed on the metal coupon 200. Advantageously, however, the teachings of the present disclosure eliminate the need for certain finishing processes of the metal coupon 200 in the part 202, such as, but not limited to, peening, heat treating, and hot isostatic pressing (HIP).

[0072] 8B and 8C illustrate positioning of the metal coupon 200 in the coupon opening 204 in the body 206 of the part 202. The metal coupon 200 can be positioned in the opening 204 in the body 206 by any method now known or later developed, such as manually via a press fit or slip fit. If desired, the metal coupon 200 can be held in place by any desired method, such as adhesive, clamps, nickel-chromium tack welds, ball tacks, resistance weld, fusion tack weld, etc.

[0073] 8D-E illustrate infiltrating the metal coupon 200 with braze material 310 to bond the metal coupon to the coupon opening 204 in the body 206, i.e., performing the brazing process. The braze material 310 may include any currently known or later developed braze composition, such as, but not limited to, GE (Alstom) B1P, Amdry™ D15, DF4B, or BRB, some of whose formulations are listed in the table below along with other braze formulations. [Table 1] Infiltrating may include any now known or later developed brazing process, such as using a vacuum brazing system, induction brazing system, and / or inert gas atmosphere heating system and related techniques. In one non-limiting example, brazing may include, for example, applying a brazing material (FIG. 8D) and applying heat (FIG. 8E) to cause the brazing material to flow by capillary action into, through, and around the metal coupon 200.

[0074] The infiltration includes injecting the brazing material 310 into at least one of the first porous region 300A based on the characteristics of the component porosity (i.e., first component porosity) of at least the first porous region 300A and the second porous region 300B based on the characteristics of the component porosity (i.e., second component porosity) of at least the second porous region 300B. If a component variable porosity region 300D (FIG. 7D) is present, the infiltration includes moving and infiltrating the brazing material 310 into the first porous region 300A based on the characteristics of the first component porosity, moving and infiltrating the variable porosity region 300D based on the characteristics of the variable porosity region 300D (e.g., porosity gradient, stepped porosity, etc.), and moving and infiltrating the second porous region 300B based on the characteristics of the second component porosity. The braze material 310 can also infiltrate the TT structure(s) 340 based on the characteristics of the TT structure porosity therein.

[0075] The different porosities of the porous regions 300A, 300B, any porosity of the TT structure(s) 340, and possibly the variable porosity region 300D, result in different brazing material 310 flow and infiltration during the brazing process. As a result of the brazing process, for example, the first porous region 300A and the second porous region 300B having the brazing material 310 therein have at least one different physical property. If the variable porous region 300D is present, it will likely have a different physical property(s) than the first and second porous regions 300A, 300B. Thus, as a result of the brazing process, in the part 202, the first porous region 300A and the second porous region 300B (and possibly the variable porosity region 300D) having the brazing material 310 therein have at least one different physical property. For example, a larger amount of brazing material 310 may result in stronger bond bond strength, higher ductility, higher thermal or electrical conductivity, and / or higher oxidation resistance, whereas a smaller amount of brazing material 310 may result in less surface roughness, lower hardness, lower bond bond strength, lower ductility, lower thermal or electrical conductivity, and / or lower oxidation resistance. In any case, controlling the amount of brazing material and the porosity of the different porous regions can control the physical properties of the final product. In one example, the porosity of the first member in the first porous region 300A may be higher (i.e., less dense) than the porosity of the second member in the second porous region 300B. In this case, infiltration includes infiltrating more brazing material 310 into the first porous region 300A than into the second porous region 300B. Depending on the braze material 310 used, among other factors, the differing porosity may customize at least one physical property of the member 202, such as bond bond strength, stress / strain resistance, ductility, wear resistance, oxidation resistance, thermal conductivity, electrical conductivity, surface roughness, hardness, and / or mass. Additionally, the multiple flow paths of the braze material 310 using the porous region 300 may reduce the likelihood of a lack of fill and / or voids along the braze joint compared to traditional narrow gap fill brazing processes due to the tight manufacturing tolerances required for narrow gap brazing.Thus, the part 202 can be at least 98% solid despite the use of a metal coupon 200 having porous region(s) 300 therein. The porosity or porosity of the TT structures 340 can also be used to customize the physical properties of those structures.

[0076] In certain embodiments, different braze materials 310 may be used on different portions of the metal coupon 200 to further customize the bonding of the metal coupon 200 within the part 202 and the physical properties of the areas of the part 202. For example, with reference to FIG. 9C, a first braze material 310A may be used on a first portion or side 326 of the part 202 and another braze material 310B different from the first braze material 310A may be used on a different portion or side 328 of the part 202. In one example, with reference to FIGS. 3, 4 and 9C, the first portion or side 326 of the part 202 may be the first (concave, pressure) side outer wall 152, 178 of the airfoil 150, 176 and the second portion or side 328 of the part 202 may be the second (convex, suction) side outer wall 154, 178 of the airfoil 150, 176. In addition to the different porous regions 300 on different portions or sides 326, 328, the different braze materials 310A, 310B can be customized to the expected environment of the part 202 at those locations. As will be appreciated, the variations in braze materials and / or porous regions possible to address different situations are vast.

[0077] Other embodiments of the method according to the present disclosure may include only forming a metal coupon 200 for repairing a part 202. In this case, as shown in FIG. 8A, the method includes creating a model of the coupon opening 204 in the body 206 of the part 202 and additively manufacturing the metal coupon 200 to at least closely fit the coupon opening 204, e.g., to have approximately the net shape of the coupon opening 204. As described herein and shown in FIGS. 7B-D, the metal coupon 200 may include at least a first porous region 300A having a first member porosity and a second porous region 300B having a second member porosity different from the first member porosity. The different first and second porosities create different physical properties after bonding the metal coupon 200 to the coupon opening 204 using a braze material 310. Additionally, the metal coupon 200 may include any version of the TT structure 340 described herein.

[0078] 8F illustrates an example optional finishing step for part 202, such as, but not limited to, machining to smooth the exterior surface and remove excess braze material. As previously mentioned, the teachings of the present disclosure may, among other things, eliminate the need for other finishing steps typically used to address residual stresses present in materials after additive manufacturing, such as, for example, peening, heat treating, and / or hot isostatic pressing (HIP).

[0079] 3, 4, and 9A-C illustrate an embodiment of a part 202 according to an embodiment of the present disclosure, with Figs. 9A-C illustrating an enlarged cross-sectional view of a metal coupon 200 within a coupon opening 204 in a body 206 of the part 202. Fig. 9A illustrates a part 202 comprising a metal coupon 200 having a single porous region 300 within a primary member 290, Fig. 9B illustrates a part 202 comprising a metal coupon 200 having two or more porous regions 300A, 300B within a primary member 290, and Fig. 9C illustrates a part 202 comprising a metal coupon 200 having two or more porous regions 300A, 300B and different braze materials 310A, 310B within a primary member 290. The part 202 includes a body 206. As discussed herein, the body 206 can have any form depending on the particular industrial application in which the part 202 is to be used. In the examples used herein, the body 206 may include a turbine rotating blade 132 (FIG. 3) or a turbine stationary nozzle 126 (FIG. 4). The metal coupon 200 is shown, for example, on the airfoil 150, 176 of the blade 132 and the nozzle 126 in FIGS. 3 and 4, respectively, but the metal coupon 200 may be in any portion of the body 206 of the part 202. The additive manufacturing (AM) metal coupon 200 has at least a first porous region 300A in a primary member 290 having a first member porosity, as described herein in connection with FIG. 7A. The brazing material 310 bonds the metal coupon 200 within the coupon opening 204 of the body 206. As shown in FIG. 9A, the brazing material 310 includes a first section 370 infiltrated into the first porous region 300A based on the characteristics of at least the first member porosity. 9B, the metal coupon 200 further includes a second porous region 300B having a second component porosity that is different from the first component porosity. The first component porosity may differ from the second component porosity in at least one of the following characteristics: percentage of open space volume to total volume, pore shape, pore size, number of pores, and / or pore connecting passages.The body 206 may have a body porosity different from one or both of the first and second member porosities and any TT structure porosity. For example, the body 206 may have a body porosity denser than both the first and second member porosities and any TT structure porosity, e.g., 100% solid. Optionally, the metal coupon 200 may include a variable porosity region 300D (shown in FIG. 9B by a dashed box) between (and possibly including a portion of) the first porous region 300A and the second porous region 300B. The variable porosity region 300D may provide a gradual change in porosity between the first member porosity and the second member porosity, e.g., in a stepwise or incremental manner.

[0080] In FIG. 9C, the braze material 310B includes a second portion 372 that has infiltrated into the second porous region 300B based at least on a characteristic of the porosity of the second member. "At least on a characteristic" of the porosity indicates that the porosity may result in different infiltration characteristics, such as braze material volume, pattern within the porosity, crystallization, and / or other characteristics. However, as understood in the art, other factors may also affect the infiltration characteristics, such as, but not limited to, the type of braze material and characteristics of the brazing process, such as temperature, pressure, and / or positional relationship of the component 202 to the metal coupon 200. As a result of the different porosities, the first porous region 300A and the second porous region 300B that include the braze material 310 have at least one different physical characteristic. The porosity may be customized to select those physical characteristics to the extent that the porosity may affect those physical characteristics. In one example, the first porous region 300A has a higher first member porosity (i.e., lower density) than the second member porosity of the second porous region 300B, and the first porous region 300A includes more brazing material 310 therein than the second porous region 300B. In another example, the first porous region 300A is adjacent to at least a portion of the edge 306 of the metal coupon 200 configured to be bonded to the body 206. The second porous region 300B may also be adjacent to the first porous region 300A. Alternatively, the second porous region 300B may also be adjacent to at least a (different) portion of the edge 306 of the metal coupon 200, possibly adjacent to the first porous region 300A. As shown in FIG. 9B, this arrangement may be advantageous to place more brazing material 310 near the brazing joint 374 to enhance the bonding adhesive bond strength of the metal coupon 200 at the coupon opening 204 in the body 206, or may allow for less oxidation at the brazing joint 374, or greater thermal conductivity at the brazing joint 374.Any of the physical properties described herein can also be customized based on different porosity and / or different brazing materials. As previously described, depending on the brazing material 310 used, different porosity can customize the physical properties of the part 202, such as bond bond strength, stress / strain resistance, ductility, wear resistance, oxidation resistance, thermal conductivity, electrical conductivity, surface roughness, hardness, and / or mass. As previously described, the metal coupon 200 can have approximately the net shape of the coupon opening 204 of the body 206 of the part 202. As shown, for example, in FIGS. 7A and 8C, the metal coupon 200 can optionally include cooling passage(s) 360 therein. The cooling passage 360 ​​can be defined in the metal coupon 200 and extend through the outer surface 308 of the metal coupon.

[0081] Although specific locations of the different porous regions 300 in the primary component 290 are illustrated herein, it is emphasized that the different porous regions may be arranged in any manner to provide different brazing material penetration characteristics and different physical properties to the component 202.

[0082] 10A-E are cross-sectional views of FIGS. 9A-C illustrating an exemplary embodiment of a metal coupon 200 having a TT structure(s) 340 in the part 202. FIGS. 10A and 10D are cross-sectional views along line 10A-10A in FIG. 9A, but with different TT structures 340. FIGS. 10B and 10E are cross-sectional views along line 10B-10B in FIG. 9B, but with different TT structures 340. And FIG. 10C shows a cross-sectional view along line 10C-10C in FIG. 9C. Although FIGS. 10A-E show a single TT structure 340, it will be appreciated that one or more may be used in any of the illustrated configurations. FIG. 10A shows a TT structure 340 with the same porosity as the porous region 300 of the primary member 290, as in FIG. 7A. The braze material 310 infiltrates the TT structure 340. FIG. 10B shows a metal coupon 200 in a part 202 with a TT structure 340 with a hollow center 380 as in FIG. 7M. FIG. 10C shows a metal coupon 200 in a part 202 with a solid TT structure 340 as in FIG. 7G. FIG. 10D shows a metal coupon 200 in a part 202 with a TT structure 340 that is porous (same porosity as the primary member 290 or different porosity (as in FIGS. 7A, 7C-D, 7J, 7N)) and has two different brazing materials 310A, 310B infiltrating the TT structure as in FIG. 9C. The brazing materials 310A-B can infiltrate the TT structure 340 from the first portion 330 and / or the second portion 332 of the primary member 290. FIG. 10E shows a metal coupon 200 in a part 202 with a TT structure 340 that is porous and includes a barrier 350 with a porous center 352 as in FIG. 7J. The braze material 310 may permeate from the first portion 330 and / or the second portion 332 of the primary component 290 into the TT structure 340 .

[0083] Although certain exemplary combinations of TT structure(s) 340 and primary member 290 arrangements have been shown in the figures, e.g., Figures 10A-E, it is emphasized that all of the various arrangements described herein are interchangeable and may be used together. Thus, although all different combinations have not been explicitly shown, it will be understood that all of the various arrangements of the TT structure(s) 340 and the porous regions of the primary member 290 may be used together in any manner.

[0084] 1-2, a turbomachine 100 including a turbine assembly 110 and at least one component 202 as described herein. The component 202 may take the form of a turbine stationary nozzle(s) 126, a turbine rotating blade(s) 132, or other component of the turbomachine 100. The metal coupons 200 may be used in newly manufactured or repaired components.

[0085] The present disclosure provides various technical and commercial advantages, examples of which are discussed herein. For repairs, additive manufacturing allows for cost-effective creation of metal coupons with custom-fit shapes where only the damaged material needs to be removed. The porous regions may provide a higher percentage of base alloy (e.g., greater than 60%) in certain areas that may result in improved physical properties compared to, for example, pre-sintered preforms. The porous regions may also provide a braze-filled weld / fused grain matrix (e.g., superalloy metal base) with higher strength compared to traditional metal grains surrounded by braze material. The multiple flow paths of braze material using the porous regions may also reduce the chance of underfill and / or voids along the braze joint compared to traditional narrow gap fill brazing processes. The porous regions may be formed with differential porosity between metal coupons to allow for a high degree of customization of braze material flow. The porous regions also accommodate a larger joint gap dimension variability compared to machined solid coupons with narrow gaps for braze material. Repairs using the teachings of the present disclosure are stronger than repairs using traditional narrow gap brazing processes and do not require specific post-repair finishing, while providing improved physical properties compared to prior art techniques such as pre-sintered preforms (PSPs). The heat transfer structure(s) can exhibit enhanced heat rejection, reduce the weight of the part, and improve the vibration response of the part.

[0086] Approximate expressions used throughout the specification and claims can be applied to modify any quantitative expression that can be permissibly changed without causing a change in the basic function to which it relates. Thus, values ​​modified by terms such as "about", "approximately", "substantially" and the like are not limited to the exact values ​​specified. In at least some instances, approximation expressions may correspond to the precision of the instrument for measuring the value. Throughout the specification and claims, range limitations may be combined and / or interchanged. Such ranges are specified and include all subranges contained therein, unless the context or language indicates otherwise. "About" or "approximately" as applied to a particular value in a range applies to both endpoints and may indicate ±10% of the stated value, unless dependent on the precision of the instrument for measuring the value.

[0087] Corresponding structures, materials, acts, and equivalents of all means or step-plus-function elements in the following claims are intended to include any structure, material, or act for performing a function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting of the disclosure in the disclosed form. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the present disclosure. The embodiments have been selected and described in order to best explain the principles and practical applications of the present disclosure, and to enable those skilled in the art to understand the present disclosure in various embodiments with various modifications as suited to the particular uses contemplated. [Explanation of symbols]

[0088] 100: turbomachine 102: compressor 104: combustor 106: combustion region 108: fuel nozzle assembly 110: turbine assembly 111: turbine 112: rotor 120: nozzle row or vane row 122: stationary casing 124: rotating blade row 126: stationary vane / nozzle 128, 171: outer platform 130: inner platform 132: rotating blades 134, 174: inner platform 136: tip shroud 140: root 142: dovetail 144: rotor wheel 146: shank 148: platform 150, 176: airfoil 151: working fluid 152, 178: pressure side (PS) outer wall 154, 180: suction side (SS) outer wall 156, 182: leading edge 158, 184: trailing edge 160: Tip 200, 200A, 200B: Metal coupon 202: Component 204: Coupon opening 206: Body 208: Component surface 210: Computer controlled metal powder additive manufacturing system / AM system 212, 214, 216, 218: Molten beam source 220: Build platform 230: Additive manufacturing control system 232: AM printer 234: Computer executable instructions / code 234O: Computer executable instructions / objects 234S: Computer executable instructions / system 236: Computer 238: Memory 240: Storage system 244: Processor unit (PU) 246: Input / output (I / O) interface 248: Bus 250: External I / O device / resource 260: Processing chamber 262: Molten beam 270: Applicator 272: Raw material 274: Gas mixture 276: Inert gas / inert gas source 280: Pump 282: Valve system 286: Filter 290: Primary component 300: Porous region 300A: First porous region 300B: Second porous region 300C: Third porous region 300D: Variable porosity region 302: Holes 304: Solid region 306: Edge 308: Outer surface 310: Braze material 330: First portion 332: Second portion 334: Gaps 340: Heat transfer structure / TT structure 342: Pins 344: Fins 350: Barrier 352: Porous center 354, 356: End barriers 360: Cooling passages 362: First end364: Second end 370: First section 372: Second section 374: Brazed joint 380: Hollow center

Claims

1. An additive manufacturing (AM) metal coupon (200) for insertion into a part (202), comprising: a primary member (290) having a member porosity of between 2% and 50% open space volume relative to a total volume of the primary member (290), the primary member (290) having a first portion (330) separated from a second portion (332) by a gap (334); at least one heat transfer structure (340) extending across the gap (334) between the first portion (330) and the second portion (332); The AM metal coupon (200).

2. 2. The metal coupon (200) of claim 1, wherein the at least one heat transfer structure (340) comprises at least one of a pin (342) and a fin (344) extending across the gap (334) between the first portion (330) and the second portion (332).

3. 3. The metal coupon (200) of claim 2, wherein the at least one heat transfer structure (340) comprises a plurality of at least one of pins (342) and fins (344) extending across the gap (334) between the first portion (330) and the second portion (332).

4. The metal coupon (200) of claim 1, wherein the at least one heat transfer structure (340) has component porosity.

5. 5. The metal coupon (200) of claim 4, further comprising a braze intrusion barrier (350) sealing a side of the at least one heat transfer structure (340), wherein a center (352) of the at least one heat transfer structure (340) has component porosity.

6. 2. The metal coupon of claim 1, wherein the at least one heat transfer structure has a heat transfer (TT) structure porosity that is different from a member porosity, and the TT structure porosity is between 2% and 50% open space volume relative to a total volume of the at least one heat transfer structure.

7. 7. The metal coupon (200) of claim 6, further comprising a braze permeation barrier (350) sealing a side of the at least one heat transfer structure (340), the braze permeation barrier (350) leaving a void of the TT structure (340) in a center (352) of the at least one heat transfer structure (340).

8. The metal coupon (200) of claim 1, wherein the at least one heat transfer structure (340) is solid.

9. The metal coupon (200) of claim 1, wherein the at least one heat transfer structure (340) is hollow.

10. 2. The metal coupon (200) of claim 1, further comprising a cooling passage (360) extending through at least a portion of the primary member (290) and having a first end (362) open to the gap (334) and a second end (364) extending through an exterior surface (308) of the primary member (290).

11. A part (202), A main body (206) an additively manufactured (AM) metal coupon (200); AM Metal Coupon (200) a primary member (290) having a member porosity of 2% to 50% open space volume relative to a total volume of the primary member (290), the primary member (290) having a first portion (330) separated from a second portion (332) by a gap (334); at least one heat transfer structure (340) extending across the gap (334) between the first portion (330) and the second portion (332); and a braze material (310) that bonds the AM metal coupon (200) at the coupon opening (204) of the body (206), the braze material (310) penetrating the primary component (290) based at least on the porosity characteristics of the component.

12. 12. The component (202) of claim 11, wherein the at least one heat transfer structure (340) comprises at least one of a pin (342) and a fin (344) extending across the gap (334) between the first portion (330) and the second portion (332).

13. 13. The component (202) of claim 12, wherein the at least one heat transfer structure (340) comprises a plurality of at least one of pins (342) and fins (344) extending across the gap (334) between the first portion (330) and the second portion (332).

14. The component (202) of claim 11, wherein the at least one heat transfer structure (340) has component porosity, and the braze material (310) at least partially penetrates the at least one heat transfer structure (340).

15. 15. The component (202) of claim 14, further comprising a braze infiltration barrier (350) sealing a side of the at least one heat transfer structure (340), wherein a center (352) of the at least one heat transfer structure (340) has component porosity, and wherein the braze material (310) at least partially infiltrates the at least one heat transfer structure (340).

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