Metal porous coupon with anchor for component, and component with that coupon

Abstract

To provide a porous metal coupon with an anchor to be secured to a component, and the component.SOLUTION: A metal coupon 200 includes an additively manufactured (AM) metal member 290 having a porous region 300 having open space volume of 2-50% relative to total volume. The metal coupon 200 includes a first section 292 of an anchor 294 configured to interact with the second section 296 of the anchor 294 in a coupon opening of a body of a component. A component including the metal coupon 200 may include the body including the coupon opening, an anchor 294 including a first section 292 at one of the AM metal coupon 200 and the body, and a second section 296 at the other of the AM metal coupon 200 and the body. At least the first and second sections 292, 296 cooperatively hold the AM metal coupon 200 in the coupon opening in the body.SELECTED DRAWING: Figure 8B

Description

Technical Field

[0001] The present disclosure generally relates to the repair and manufacture of components, and more specifically to a porous metal coupon with an anchor for fixing to a component.

Background Art

[0002] Industrial components sometimes need repair. For example, high-temperature gas path components used to direct a working fluid for energy generation in turbomachinery may need repair. High-temperature gas path components can take various shapes, such as turbine rotor blades or stationary vanes that include airfoils for directing a working fluid for energy generation. The rotor blades are coupled to the turbine rotor and act to rotate the turbine rotor, and the stationary vanes are coupled to the casing of the turbomachinery and direct the working fluid toward the rotor blades.

[0003] Additive manufacturing, such as direct metal laser melting (DMLM) or selective laser melting (SLM), has emerged as a reliable manufacturing method for industrial components. With the advent of additive manufacturing technology, it has also become possible to replace a part of a component, such as a part of the leading edge or trailing edge of a nozzle of a turbomachinery. For example, a part of the leading edge of a nozzle of a turbomachinery can be removed leaving a notch in the nozzle, and a new section (referred to herein as a "coupon") can be joined to the notch. The coupon is additively manufactured to have a shape that at least generally matches the shape of the notch. This coupon can replace a part of a used turbomachinery nozzle or be added as part of a new turbomachinery nozzle.

[0004] However, the replacement coupon is made of the same material and exterior structure as the removed portion of the part. Therefore, the replacement coupon has some of the same drawbacks as the original part and / or notch, and there is no improvement in overall performance characteristics such as coupon strength, oxidation resistance, cyclic fatigue, stress / strain resistance, ductility, wear resistance, thermal conductivity or electrical conductivity and / or mass loss. When using one type of brazing material to bond the replacement coupon to the part, it is also impossible to improve additional performance characteristics related to the joint, such as the above-mentioned overall performance characteristics, further improvement in joint adhesion strength and reliability, and reduction of machining / blending operations required after brazing. Also, using a coupon of substantially the same material as the removed notch makes it impossible to reduce the high material cost of the replacement coupon.

SUMMARY OF THE INVENTION

[0005] All aspects, specific examples and features listed below can be combined in technically possible ways.

[0006] One aspect of the present disclosure provides a metal coupon, where the metal coupon is an additive manufacturing (AM) metal member having a porous region with a void space volume of 2 - 50% relative to the total volume of the porous region, and a first section of an anchor configured to interact with a second section of complementary shape of an anchor of the body of the part to which the metal coupon is to be bonded.

[0007] Another aspect of the present disclosure includes any of the above aspects, and the first section of the anchor is an elongated protrusion.

[0008] Another aspect of the present disclosure includes any of the above aspects, and the elongated protrusion has any of a male dovetail shape, a polygonal shape, and a curved shape.

[0009] Another aspect of the present disclosure includes any of the above aspects, and the elongated protrusion extends at least partially along the side surface of the AM metal member.

[0010] Another aspect of the present disclosure includes any of the above aspects, and the elongated protrusion includes a plurality of elongated protrusions.

[0011] Another aspect of the present disclosure includes any of the above aspects, and the first section of the anchor is an elongated opening.

[0012] Another aspect of the present disclosure includes any of the above aspects, and the elongated opening has any one of a female dovetail shape, a polygonal shape, and a curved shape.

[0013] Another aspect of the present disclosure includes any of the above aspects, and the elongated opening extends at least partially along the side surface of the AM metal member.

[0014] Another aspect of the present disclosure includes any of the above aspects, and the first section includes at least a part of the porous region.

[0015] Aspects of the present disclosure include a component, the component including a main body including an opening, a metal additive manufacturing (AM) coupon having a porosity of 2 to 50% void space volume with respect to the total volume of the porous region, a first section provided on one of the AM metal coupon or the main body, and a second section provided on the other of the AM metal coupon or the main body, an anchor including at least the first section and the second section cooperating to hold the AM metal coupon in the coupon opening of the main body, and a brazing material for bonding the AM metal coupon to the coupon opening of the main body, the brazing material infiltrating the porous region based at least on the porosity characteristics.

[0016] Another aspect of the present disclosure includes any of the above aspects, the first section of the anchor is an elongated protrusion, and the second section of the anchor is an elongated opening having a shape complementary to the elongated protrusion and configured to receive the elongated protrusion of the first section.

[0017] Another aspect of the present disclosure includes any of the above aspects, and the elongated protrusion and the elongated opening are any of complementary male-female dovetail shapes, male-female polygonal shapes, or male-female curved shapes.

[0018] Another aspect of the present disclosure includes any of the above aspects, and the first section includes at least a part of the porous region.

[0019] Another aspect of the present disclosure includes any of the above aspects, the first section extends at least in part or partially at a first distance along one side surface of the AM metal coupon and the body, the second section extends at a second distance along the other side surface of the AM metal coupon and the body, and the first distance and the second distance are equal.

[0020] Another aspect of the present disclosure includes any of the above aspects, the first section and the second section each include a recess, and the anchor further includes a locking element configured to engage the recess of the first section and the recess of the second section to cooperatively hold the AM metal coupon in the opening of the body.

[0021] Aspects of the present disclosure include a turbomachine, the turbomachine including a turbine assembly and at least one component within the turbine assembly, the component including a body including a coupon opening, a metal additive manufacturing (AM) coupon including a porous region having a porosity of 2 to 50% void space volume relative to the total volume of the porous region, an anchor including a first section provided on one of the AM metal coupon or the body and a second section provided on the other of the AM metal coupon or the body, the anchor being configured such that at least the first section and the second section cooperate to hold the AM metal coupon in the coupon opening of the body, and a brazing material for bonding the AM metal coupon to the coupon opening of the body, the brazing material being infiltrated into the porous region based at least on the characteristics of the porosity.

[0022] Another aspect of the present disclosure includes any of the above-described aspects, wherein the first section of the anchor is an elongated protrusion, and the second section of the anchor is an elongated opening configured to receive the elongated protrusion of the first section.

[0023] Another aspect of the present disclosure includes any of the above-described aspects, wherein the elongated protrusion and the elongated opening are any of complementary male-female dovetail, male-female polygonal, or male-female curved shapes.

[0024] Another aspect of the present disclosure includes any of the above-described aspects, wherein the first section extends at least partially distanced along one side of the AM metal coupon and the body, and the second section extends distanced along the other side of the AM metal coupon and the body.

[0025] Another aspect of the present disclosure includes any of the above-described aspects, wherein the first section includes at least a portion of the porous region.

[0026] Another aspect of the present disclosure includes a method of coupling a metal coupon to a component having a body with a coupon opening, the method comprising: additive manufacturing the metal coupon, the metal coupon including a porous region having a porosity of 2 to 50% void space volume relative to the total volume of the porous region, and an anchor including a first section provided on one of the AM metal coupon or the body and a second section provided on the other of the AM metal coupon or the body, wherein at least the first section and the second section cooperate to hold the AM metal coupon in the coupon opening of the body; placing the metal coupon in the coupon opening of the body of the component, the anchor holding the metal coupon in the coupon opening; and infiltrating the metal coupon with a brazing material to couple the metal coupon to the coupon opening of the body, the infiltrating including infiltrating the porous region with the brazing material based at least on the porosity characteristics.

[0027] Another aspect of the present disclosure includes any of the above aspects, and further includes the steps of forming a coupon opening in the body configured to receive a metal coupon before additive manufacturing, and creating a model of the coupon opening, wherein the additive manufacturing includes manufacturing a metal coupon based on the model of the coupon opening.

[0028] Another aspect of the present disclosure includes any of the above aspects, and the additive manufacturing includes manufacturing a metal coupon in a near-net shape of the coupon opening based on the model of the coupon opening.

[0029] Another aspect of the present disclosure includes any of the above aspects, wherein the first section of the anchor is an elongated protrusion, and the second section of the anchor is an elongated opening configured to receive the elongated protrusion of the first section.

[0030] Another aspect of the present disclosure includes any of the above aspects, wherein the elongated protrusion and the elongated opening are any of complementary male-female dovetail shapes, male-female polygonal shapes, or male-female curved shapes.

[0031] Another aspect of the present disclosure includes any of the above aspects, wherein the first section extends at least partially along one side surface of the metal coupon and the body at a first distance, and the second section extends at a second distance along the other side surface of the metal coupon and the body, and overall, the first and second distances are the same dimension as the thickness of the coupon opening.

[0032] Another aspect of the present disclosure includes any of the above aspects, wherein the first section includes at least a portion of the porous region.

[0033] Combinations of two or more aspects described in this disclosure, including the aspects described in the Summary of the Invention section of this invention, may also be used as embodiments not specifically described herein. That is, all of the embodiments described in this application can be combined with each other.

[0034] The details of the above embodiments are described in the accompanying drawings and the following description. Other features, aspects, and advantages will become apparent from the detailed description of the invention, the drawings, and the claims.

Brief Description of the Drawings

[0035] Regarding the above other features of the present disclosure, a better understanding can be obtained by referring to the following detailed description in conjunction with the accompanying drawings that describe various embodiments of the present disclosure.

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[0036] The drawings of the present disclosure are not necessarily to scale. The drawings merely illustrate typical aspects of the present disclosure and do not limit the technical scope of the present disclosure. In the drawings, like reference numerals represent like components across multiple drawings.

Best Mode for Carrying Out the Invention

[0037] First, in order to clearly explain the technical content of the present disclosure, it is necessary to select terms when referring to and describing the mechanical components related to the exemplary uses of turbomachines. As much as possible, common terms in the art are used in accordance with their ordinary meanings. Unless otherwise stated, such terms should be construed broadly in accordance with the context of this application and the appended claims. It will be apparent to those skilled in the art that there are often many cases where several different or overlapping terms are used to refer to a certain component. In this specification, even if something is described as a single member, it may be described as consisting of a plurality of components in another context. Or, even if something is described as including a plurality of components in one part of this specification, it may be described as a single member in another part.

[0038] Furthermore, although several descriptive terms are repeatedly used in this specification, it will be useful to define these terms at the beginning of this section. These terms and their definitions are as follows, unless otherwise specified. The terms "downstream" and "upstream" used in this specification are terms indicating directions related to the flow of a fluid (for example, the flow of a working fluid through a turbine engine, or the flow of air through a combustor or a coolant through one of the component systems of a turbine). The term "downstream" corresponds to the direction in which the fluid flows, and the term "upstream" refers to the direction opposite to the flow (that is, the direction from which the fluid flows). The terms "front" and "rear" refer to directions that are not further specified. "Front" indicates the front of the turbomachine or the compressor end, and "rear" indicates the rear of the turbomachine or the turbine end.

[0039] Furthermore, in this specification, as described below, several descriptive terms are repeatedly used. The terms "first", "second", and "third" are used interchangeably to distinguish one component from another and do not indicate the position or importance of individual components.

[0040] The terms used in this specification are for the purpose of describing particular embodiments only and are not intended to limit the disclosure. In this specification, even if described in the singular form, it means including the plural cases as well, unless otherwise clear from the context. In this specification, the terms "comprising", "including" and / or "having" indicate the presence of the described features, integers, steps, operations, components and / or parts, and do not exclude the presence or addition of one or more other features, integers, steps, operations, components, parts and / or groups thereof. The terms "optional" or "suitably" mean that the event described following the term may or may not occur, or the feature described following the term may or may not be present, and such description includes the case where the event occurs or the feature is present and the case where the event does not occur or the feature is not present.

[0041] When a component or layer is "on", "engaged with", "connected to", "coupled to" or "attached to" another component or layer, it may be located directly on the other component or layer, directly engaged with, connected to, coupled to or attached to the other component or layer, or there may be intervening components or layers. In contrast, when a component is "directly on", "directly engaged with", "directly connected to" or "directly coupled to" another component or layer, there are no intervening components or layers. Other terms used to describe the relationship between components (e.g., "between" and "directly between", "adjacent" and "directly adjacent", etc.) are interpreted in the same way. The verb forms of "coupled" and "attached" may be used synonymously.

[0042] As described above, the present disclosure provides a metal coupon comprising an additive manufacturing (AM) metal member having a porous region with a porosity of 2 to 50% relative to the total volume. As used herein, a "coupon" may include any component configured to be disposed within an opening of a component body as part of an original manufacture or repair, i.e., an insertable component. The metal coupon also includes a first section of an anchor configured to interact with a complementary-shaped opening of the component body. The component includes the metal coupon and a body including the opening of the coupon. The anchor includes a first section of the AM metal coupon and the body or a first section thereon, and a second section of the AM metal coupon and the body or a second section on the body. At least the first section and the second section cooperate to hold the AM metal coupon within the coupon opening of the body. A brazing material connects the coupon to the coupon opening of the body. The brazing material infiltrates the porous region. One or more porosities of the metal coupon are configured to direct the flow of one or more brazing materials to create different physical properties than were previously possible, e.g., by directing more brazing material to where needed, directing the brazing material into a special shape, and / or enabling the use of multiple brazing materials. When used for repair, the customized AM metal coupon does not suffer the same drawbacks as the original component and / or cutout, and can be customized using brazing materials to change, e.g., joint adhesive bond strength, coupon strength, stress / strain resistance, ductility, wear resistance, oxidation resistance, cyclic fatigue, thermal conductivity, electrical conductivity, surface roughness, hardness, and mass. This repair is stronger than conventional narrow-gap brazing processes, does not require a specific post-repair finish, and has improved physical properties compared to current technologies such as pre-sintered preforms (PSPs). One or more brazing materials can be used to bond a replacement coupon to the component, improving performance characteristics related to the joint, such as joint adhesion strength and reliability, and reducing the necessary post-brazing machining / blending. Additionally, the use of a porous AM metal coupon can also lead to cost savings in materials, such as reducing the use of expensive base materials for the metal coupon.The anchor serves to position, align, and / or hold a metal coupon relative to a coupon opening in the body of the component.

[0043] FIG. 1 shows a schematic view of an exemplary industrial machine, which can include components in accordance with 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 (i.e., rotor 112) 112. In one embodiment, the turbomachine 100 is a 7HA.03 engine commercially available from GE Vernoa. The present disclosure is not limited to any particular GT system and can be implemented with respect to other engines, such as other HA, F, B, LM, GT, TM, and E class engine models from GE Vernoa, as well as engine models from other companies. The present disclosure is not limited to any particular turbomachine and can be applied to any industrial component that uses coupons during manufacturing or repair.

[0044] During operation, air flows through the compressor 102 and compressed air is supplied to the combustor 104. Specifically, the compressed air is supplied to a fuel nozzle assembly 108 built into the combustor 104. The assembly 108 is in fluid communication with the combustion region 106. The fuel nozzle assembly 108 is also in fluid communication with a fuel source (not shown in FIG. 1) and guides fuel and air into the combustion region 106. The combustor 104 ignites and burns the fuel. The combustor 104 is in fluid communication with the turbine assembly 110. The turbine assembly 110 includes a turbine 111 that is rotatably coupled to the rotor 112 to drive the rotor 112. The compressor 102 is also rotatably coupled to the rotor 112. In an exemplary embodiment, there are a plurality of combustors 104 and fuel nozzle assemblies 108.

[0045] FIG. 2 shows a cross-sectional view of an exemplary turbine assembly 110 of a turbomachine 100 (FIG. 1) that can be used in the gas turbine system of FIG. 1. The turbine 111 of the turbine assembly 110 includes a row 120 of nozzles or vanes coupled to the stationary casing 122 of the turbomachine 100 and a row 124 of blades axially adjacent thereto. The stationary vanes or nozzles 126 can be held within the turbine assembly 110 by a radially outer platform 128 and a radially inner platform 130. The row 124 of blades of the turbine assembly 110 includes rotating blades 132 coupled to the rotor 112 and rotating therewith. The rotating blade 132 may include a radially inner platform 148 (blade root) coupled to the rotor 112 and, optionally, a radially outer tip 136 (blade tip). As used herein, the term "component" generally refers to a structure that can use a stationary nozzle 126, a rotating blade 132, or a metal coupon including one or more porous regions according to the present disclosure.

[0046] FIGS. 3 and 4 show exemplary components to which the teachings of the present disclosure can be applied, such as high temperature gas path components of a turbomachine. FIG. 3 shows a perspective view of a turbine rotor blade 132 of a type that can use an embodiment of the present disclosure. The turbine rotor blade 132 includes a root 140 by which the rotor blade 132 is attached to the rotor 112 (FIG. 2). The root 140 can include a dovetail 142 configured to be mounted in a corresponding dovetail slot on the outer periphery of the 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 the platform 148, and the platform 148 is disposed at the connection of the airfoil 150 and the root 140 and defines a part of the flow path through the turbine assembly 110. The airfoil 150 is the active part of the rotor blade 132 that receives the flow of the working fluid 151 (i.e., high temperature combustion gas) (FIG. 2) and causes rotor disk rotation. The airfoil portion 150 of the rotating blade 132 includes a concave-shaped positive pressure side (PS) outer wall 152 and a convex-shaped negative pressure side (SS) outer wall 154 on the opposite side in the circumferential or transverse direction, and extends axially between the leading edge 156 and the trailing edge 158. The side outer walls 152 and 154 extend radially from the platform 148 to the outer tip 160, and the tip 60 may or may not include a tip shroud 136 (FIG. 2).

[0047] FIG. 4 is a perspective view of a stationary nozzle 126 of a type that can be used in an embodiment of the present disclosure. The stationary nozzle 126 includes an outer platform 170, by which the stationary nozzle 126 is attached to the stationary casing 122 (FIG. 2) of the turbomachine. The outer platform 170 may include any attachment configuration known in the art or developed in the future for attachment to a corresponding mount of the casing. The stationary nozzle 126 may further include an inner platform 174 disposed between adjacent turbine rotor blades 132 (FIG. 3) and platforms 148 (FIG. 3). The platforms 170, 130 define respective portions of the outer and inner boundaries of the flow path through the turbine assembly 110. The airfoil portion 176 is the active component of the stationary nozzle 126 that receives the flow of the working fluid and directs the flow towards the turbine rotor blade 132 (FIG. 3). The airfoil portion 176 of the stationary nozzle 126 includes a concave-shaped positive pressure side (PS) outer wall 178 and a convex-shaped negative pressure side (SS) outer wall 180 on the opposite side in the circumferential or transverse direction, and extends axially between the leading edge 182 and the trailing edge 184. The side outer walls 178 and 180 also extend radially from the platform 170 to the platform 174.

[0048] The blade 132 or the nozzle 126 may include an internal cooling structure including a coolant supply source, such as passages, conduits, and other structures for delivering the coolant to its surface for film cooling. Examples of the coolant include air from the compressor 102.

[0049] The embodiments of the disclosure described in this application include aspects applicable to stationary nozzles 126, turbine rotor blades 132, and / or any industrial parts to which other coupons are used. Figures 3 and 4 also show an exemplary additive manufacturing (AM) metal coupon 200 (hereinafter, "metal coupon 200" or "AM metal coupon 200") in component 202. More specifically, metal coupon 200 is within coupon opening 204 of body 206 of component 202. "Coupon opening 204 of body 206" may be any sized void within body 206 up to and including the removed portion of body 206 (e.g., tip shroud). For example, metal coupon 200 may be disposed in coupon opening 204 at trailing edges 158, 184 of blade 132 or nozzle 126, respectively. Alternatively, metal coupon 200 may be disposed in coupon opening 204 at leading edges 156, 182 of blade 132 or nozzle 126, respectively. Metal coupon 200 may also be present at the tip of blade 132 or platforms 170, 174 (shown in FIG. 4) of nozzle 126. However, metal coupon 200 may be used in any coupon opening 204 within body 206 of component 202. Body 206 may be any part of component 202 or, alternatively, the entire component.

[0050] The laminated formed metal coupon 200 having a porous region of 1 or more can be laminated and formed using any currently known or future-developed technology capable of forming a porous region. FIG. 5 shows a schematic / block diagram of an exemplary computerized metal powder laminated forming system 210 (hereinafter, “AM system 210”) for generating the metal coupon 200 or a plurality of metal coupons 200A, 200B (only one layer thereof is shown). In the present disclosure, the formation of the metal coupon 200 using a plurality of molten beam sources 212, 214, 216, 218 will be described. However, it will be apparent that the teachings of the present disclosure can be equally applied to the formation of a plurality of coupons 200A, 200B (illustrated) using any number of molten beam sources. In this example, the AM system 210 is arranged for direct metal laser melting (DMLM). The teachings of the present disclosure in general can be similarly applied to other forms of metal powder laminated forming such as powder bed fusion bonding, direct metal laser sintering (DMLS), electron beam melting (EBM), selective laser sintering (SLS), selective laser melting (SLM), and perhaps other forms of laminated forming (i.e., those other than metal powder applications). The coupons 200A, 200B are shown as rectangular components, but the laminated forming process can be easily adapted to manufacture coupons of any shape, a wide variety of different coupons, and a large number of coupons on the build platform 220.

[0051] The AM system 210 generally includes a layer manufacturing control system 230 (the "control system") and an AM printer 232. As will be described below, the control system 230 executes a set of computer-executable instructions or code 234 to generate a coupon 200 using a plurality of melt beam sources 212, 214, 216, 218. In the example shown in the figure, the four melt beam sources include four lasers. However, the teachings of the present disclosure are applicable to any melt beam source, such as an electron beam, a laser, etc. The control system 230 is shown implemented in a computer 236 as computer program code. In this regard, the computer 236 is shown including a memory 238 and / or a storage system 240, a processor unit (PU) 244, an input / output (I / O) interface 246, and a bus 248. Also, the computer 236 is shown in communication with an external I / O device / resource 250. Generally, the processor unit (PU) 244 executes the computer program code 234 stored in the memory 238 and / or the storage system 240. While executing the computer program code 234, the processor unit (PU) 244 can read and write data between the memory 238, the storage system 240, the I / O device 250, and / or the AM printer 232. The bus 248 provides a communication link between each object within the computer 236, and the I / O device 250 can include any device that enables a user to interact with the computer 236 (e.g., a keyboard, a pointing device, a display, etc.). The computer 236 represents only various possible combinations of hardware and software. For example, the processor unit (PU) 244 may comprise a single processing unit or may be distributed over one or more locations, such as one or more processing units on a client and a server. Similarly, the memory 238 and / or the storage system 240 may reside in one or more physical locations.The memory 238 and / or the storage system 240 can comprise 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), and the like. The computer 236 can include any type of computing device, such as an industrial controller, a network server, a desktop computer, a laptop, a handheld device, and the like.

[0052] As described above, the AM system 210, particularly the control system 230, executes the code 234 to generate one or more metal coupons 200. The code 234 can 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 one or more metal coupons 200 physically generated by the AM printer 232. As described herein, the additive manufacturing process begins with a non-transitory computer-readable storage medium (such as the memory 238, the storage system 240, etc.) that stores the code 234. The computer-executable instructions 234S for operating the AM printer 232 can include any currently known or future-developed software code capable of operating the AM printer 232.

[0053] A set of computer-executable instructions 234O that define one or more metal coupons 200 may include an accurately defined 3D model of the coupon 200 and can be generated from well-known computer-aided design (CAD) software systems such as AutoCAD®, TurboCAD®, DesignCAD 3DMax. In this regard, the code 234O can include any file format known currently or developed in the future. Further, the code 234O representing the metal coupon 200 may be converted between different formats. For example, the code 234O may include an STL (Standard Tessellation Language) file created for a stereolithography CAD program of 3D Systems, or an American Society of Mechanical Engineers (ASME) standard additive manufacturing file (AMF), an extensible markup language (XML)-based format designed to describe any three-dimensional shape and composition to be manufactured on any AM printer by any CAD software. The code 234O representing the metal coupon 200 can, if necessary, also be converted into and transmitted as a set of data signals, received as a set of data signals, converted into code, or stored. The code 234O may be configured, according to an embodiment of the present disclosure, to form boundaries and internal sections in the overlapping field region as described later. In any case, the code 234O may be an input to the AM system 210 and may be from a component designer, an intellectual property (IP) provider, a design company, an operator or owner of the AM system 210, or other suppliers. In any case, the control system 230 executes the codes 234S and 234O, divides one or more metal coupons 200 into a series of thin slices, and stacks them into successive layers of material using the AM printer 232.

[0054] The AM printer 232 may include a sealed processing chamber 260 to supply a controlled atmosphere for printing the metal coupon 200. The build platform 220 on which the metal coupon 200 is formed is disposed within the processing chamber 260. A number of melt beam sources 212, 214, 216, 218 are configured to melt a layer of metal powder on the build platform 220 to produce the coupon 200. Although four melt beam sources 212, 214, 216, 218 are illustrated, the teachings of the present disclosure are applicable to systems using any number (e.g., 1, 2, 3, or 5 or more) of beam sources. Each melt beam source 212, 214, 216, 218 may have a field that includes non-overlapping regions that can exclusively melt the metal powder, or may include one or more overlapping regions where the metal powder can be melted by two or more beam sources. In this regard, each melt beam source 212, 214, 216, 218 may generate a melt beam that fuses the particles for each slice defined by the code 234O. For example, in FIG. 5, it is shown that the melt beam source 212 creates a layer of the metal coupon 200 in one region using the melt beam 262, and the melt beam source 216 creates a layer of the metal coupon 200 in another region using the melt beam 262'. Each melt beam source 212, 214, 216, 218 is calibrated in any currently known or future developed method. That is, each melt beam source 212, 214, 216, 218 correlates the predicted position of the laser beam or electron beam relative to the build platform 220 with its actual position to provide individual position corrections (not shown) to ensure its individual accuracy. In one embodiment, each of the plurality of melt beam sources 212, 214, 216, 218 may create melt beams (e.g., 262, 262') having the same cross-sectional dimensions (e.g., shape and size during operation), output, and scanning speed.

[0055] Continuing with reference to FIG. 5, the applicator (or recoater blade) 270 can create a thin layer of the raw material 272 spread as a blank canvas, on which each of the successive slices of the final metal coupon 200 is created. The various parts of the AM printer 232 can be moved to accommodate each new layer added, for example, after each layer, the build platform 220 can be lowered and / or the chamber 260 and / or the applicator 270 can be raised. This process can use various raw materials in the form of fine-grained metal powders, and the stock of raw materials can be held within the chamber 260 accessible by the applicator 270. In this case, the coupon 200 can be made of metal, and the metal can include pure metals or alloys. In one example, the metal can be substantially any non-reactive metal powder, i.e., a non-explosive or non-conductive powder, such as, but not limited to, cobalt-chromium-molybdenum (CoCrMo) alloy, stainless steel, austenitic nickel-chromium-based alloys, such as nickel-chromium-molybdenum-niobium alloy (NiCrMoNb) (e.g., Inconel 625 or Inconel 718), nickel-chromium-iron-molybdenum alloy (NiCrFeMo) (e.g., Hastelloy® X available from Haynes International), or nickel-chromium-cobalt-molybdenum alloy (NiCrCoMo) (e.g., Haynes282 available from Haynes International), etc. Other possibilities include, for example, Rene 108, CM247LC, MarM247, and other precipitation-hardened (PH) nickel-based alloys, etc.

[0056] The processing chamber 260 is filled with an inert gas such as argon or nitrogen and is controlled to suppress oxygen to a minimum or completely remove it. The control system 230 is configured to control the flow of the gas mixture 274 in the processing chamber 260 from a source of the inert gas 276. In this case, the control system 230 may control the pump 280 and / or the flow valve system 282 for the inert gas to control the content of the gas mixture 274. The flow valve system 282 may include one or more computer - controllable valves, flow sensors, temperature sensors, pressure sensors, etc. that can accurately control the flow of a specific gas. The pump 280 can be provided regardless of the presence or absence of the valve system 282. When the pump 280 is omitted, the inert gas can simply enter a conduit or manifold prior to introduction into the processing chamber 260. The source of the inert gas 276 can take the form of any conventional source for the materials contained therein, such as a tank, a storage layer, or other source. Any sensor (not shown) necessary to measure the gas mixture 274 may be provided. The gas mixture 274 can be filtered using a filter 286 in a conventional manner.

[0057] During operation, a build platform 220 with metal powder thereon is provided in the processing chamber 260, and the control system 230 controls the flow of the gas mixture 274 in the processing chamber 260 from a source of the inert gas 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 produce the metal coupon 200 according to the embodiments of the present disclosure.

[0058] Although a particular AM system 210 has been described herein, the teachings of the present disclosure are not limited to a particular additive manufacturing system or method. Further, although the teachings of the present disclosure relate to an additive manufactured metal coupon 200, the component 202 can be manufactured by any method known currently or developed in the future, such as additive manufacturing (presumably similar to that described for the metal coupon 200), casting, or other methods. The component 202 may include any of the materials listed herein with respect to the metal coupon 200.

[0059] Figures 7A - D, Figures 8A - C, Figures 9A - C, Figures 10A - C, Figures 11A - C, Figures 12A - D, Figures 13A - D, and Figures 14A - B show diagrams of exemplary additive manufacturing (AM) metal coupons 200 that include an additive manufacturing (AM) metal member 290 having a porous region 300 (with pores 302). As further described herein, the metal coupon 200 also includes a first section 292 of an anchor 294 configured to interact with a complementary-shaped second section 296 of the anchor 294 (i.e., complementary in shape to the first section 292) at a coupon opening 204 in a body 206 of a component 202 to which the metal coupon 200 is attached. More specifically, the second section 296 of the anchor 294 can be within the coupon opening 204 in the body 206 of the component 202 to which the metal coupon 200 is attached. The first section 292 of the anchor 294 may include at least a portion of the porous region 300. The porous region 300 can take various forms shown in the various drawings. For example, Figures 7A - D show a metal coupon 200 having a single porous region 300 of a first porosity (the entire coupon 200 having the first porosity). Figures 8A - C show a metal coupon 200 having a plurality of (laminar) porous sub-regions 314A - B having different porosities. Figures 9A - C show a metal coupon 200 having one or more porous sub-regions 314A - B having different porosities and a solid region 304. Figures 10A - C show a metal coupon 200 having a variable porous region 314D between a first porous sub-region 314A and a second porous sub-region 314B. Figures 11A - C show a metal coupon 200 having a plurality of (opposing) porous sub-regions 314A - B having different porosities. The metal coupon 200 in the drawings shows a shape configured to be disposed at a coupon opening 204 at a trailing edge 158 or 184 of a blade 132 or nozzle 126, or at a leading edge 156 or 182 of a blade 132 or nozzle 126, as shown in Figures 3 and 4. The metal coupon 200 can also be present at any tip (not shown) of a blade 132 or platform 170 (shown), any tip (not shown) of a nozzle 126, 174, or a wing.However, it is emphasized that the metal coupon 200 can be used at any coupon opening 204 in any part of the body 206 of any component 202.

[0060] As used herein, "porosity" is the ratio of the volume of void space to the total volume of the marked structure (e.g., porous region, metal coupon, etc.). Typically, in this regard, porosity is described as a percentage of the volume of void space to the total or entire volume of the marked structure. Void space is the empty region within the solid material, referred to herein as "pores" 302, and may include interconnected passageways within the material of the marked structure. Thus, the "porous region" of the metal coupon 200 has a solidity of less than 100% and includes void space in the form of pores 302 and / or interconnected passageways. The porous metal coupon 200 may include solid regions, but also includes one or more porous regions with a solidity of less than 100%. In this specification, the three-dimensional boundary of a porous region or sub-region for specifying the "total volume" of the porous region or sub-region is determined by the location where a change in porosity of more than 2% occurs with respect to an adjacent region or sub-region within the metal coupon 200 and / or the location where the edge of the metal coupon 200 exists. "Volume of void space" generally refers to the empty (i.e., vacant, void, empty space, and / or not filled with material) three-dimensional space within a region or sub-region. As used herein, "different porosities" or "porosity difference" generally means variations in various characteristics such as the percentage of the volume of void space to the total volume, the number of pores 302 within a given volume, the volume (i.e., size) of the pores 302, the shape of the pores 302, and variations in the connecting passageways (referred to herein as "pore connecting passageways") between pores 302 that may not be recognizable as actual discrete pores. As a non-limiting example, the pore diameter is, for example, 1.07×10 -6 ~8.58×10 - 3mm 3 (6.54×10 -11 ~5.24×10 -7It can be within the range of (cubic inches), or as another non-limiting example, the pore diameter can be within the range of 0.0127 mm to 0.254 mm (0.0005 inches to 0.01 inches). In the drawings, different porous regions or sub-regions are typically shown as continuous or in contact with each other, but they may be separated from each other (e.g., by a solid region therebetween). That is, a single metal coupon may include one or more isolated non-contact porous regions or sub-regions. The terms "region" and / or "sub-region" can be used interchangeably to indicate a change in porosity. For example, it will be apparent that the difference in porosity is not based solely on the percentage of the volume of the cavity space with respect to the total volume, such as due to differences in pore shape or pore connection passages. However, when comparing the degree of difference in porosity (e.g., high or low), the difference referred to is solely related to volume characteristics, i.e., the difference in the percentage of the volume of the cavity space with respect to the total volume.

[0061] The porous metal coupon 200 can be formed to have different porous regions with different porosities (which may or may not include one or more porous sub-regions with different porosities) using the AM system 210 described herein or other metal additive manufacturing systems or methods capable of forming porous metals. With respect to the operation of the AM system 210, the melt beam sources 212, 214, 216, 218 can be programmed intermittently such that the metal is not sintered and metal powder remains instead of solid material. This process may include in the build file (i.e., code 234O) overlapping the laser field regions in various amounts and / or designing the pores 302. The less the overlap of each laser scan, the higher the porosity, and the more the laser overlap between a series of scans, the lower the porosity. To adjust the porosity, the laser spot size, scan speed, focus, and power can also be controlled. More specifically, additive manufacturing involves using the AM system 210 having one or more melt beam sources 212, 214, 216, 218 to fuse layers of metal powder and adjusting the system parameters to control the porosity of two or more porous regions. Adjusting the parameters can include one or more of adjusting the amount of overlap of the melt regions of one or more melt beams 262, 262' (FIG. 5) from the beam sources 212, 214, 216, 218, adjusting the system scan speed, or adjusting one or more of the size, focus, or power of the melt beam spot. When the unfused metal powder is removed from the metal coupon 200, the pores 302 remain along with the interconnected passageways between the pores 302, and one or more porous regions are formed in the metal coupon 200. In any case, the additive manufacturing of the metal coupon 200 can be controlled to produce the desired porosity for any number, shape, and / or size of porous regions within the desired layer of one or more metal coupons 200.

[0062] Figures 6A - 6D show schematic top views of sample metal coupons 200 having various porosities. Pores 302 are shown as dark void spaces in the drawings. Figure 6A shows a sample metal coupon 200 having a first porosity with a void space volume of about 40% relative to the total volume of the sample (generally having a low amount of void space and a large or large - sized pore 302), Figure 6B shows a sample metal coupon 200 having a first porosity with a void space volume of about 30% relative to the total volume of the sample, Figure 6C shows a sample metal coupon 200 having a first porosity with a void space volume of about 20% relative to the total volume of the sample, and Figure 6D shows a sample metal coupon 200 having a first porosity with a void space volume of about 10% relative to the total volume of the sample (generally having a low amount of void space). Each porous region can have a void space volume of 2% - 50% (i.e., 2 - 50% void space and the remaining 50 - 98% solid) relative to the total volume of the porous region. In other embodiments, each porosity can be a void space volume of 10% - 40% (i.e., 10% - 40% void space and the remaining 60 - 90% solid) relative to the total volume of the porous region 300. In other embodiments, the porous region has a porosity within 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% - 45%, 2% - 40%, 2% - 35%, 2% - 30%, 2% - 25%, 2% - 20%, 5% - 45%, 5% - 40%, 5% - 35%, 5% - 30%, 5% - 25%, 5% - 20%, 10% - 45%, 10% - 40%, 10% - 35%, 10% - 30%, 10% - 25%, 10% - 20%, 15% - 45%, 15% - 40%, 15% - 35%, 15% - 30%, 15% - 25%, 15% - 20%, 10% - 50%, 20% - 50%, 25% - 50%, 30% - 50%, 35% - 50% or 40% - 50%. As described herein, other ranges of porosity are also possible.

[0063] In FIGS. 7A - C, 8A - C, 9A - C, 10A - C, and 11A - C, the "A" and "B" figures show perspective views of the metal coupon within the component according to embodiments of the present disclosure, and the "C" figures show top - down views of the metal coupon within the component according to embodiments of the present disclosure. FIG. 7D shows a top - down view similar to FIG. 7C. In FIGS. 12A - D, the "A" and "B" figures show perspective views of the metal coupon, FIG. 12C shows a cross - sectional view of the metal coupon 200 of FIGS. 12A - B at the coupon opening 204 as observed along the line of sight 12C - 12C of FIG. 12A, and FIG. 12D shows a cross - sectional view of the metal coupon 200 of FIGS. 12A - B at the coupon opening 204 as observed along the line of sight 12D - 12D of FIG. 12A. Similarly, in FIGS. 13A - D, the "A" and "B" figures show perspective views of the metal coupon, FIG. 13C shows a cross - sectional view of the metal coupon 200 of FIGS. 13A - B at the coupon opening 204 as observed along the line of sight 13C - 13C of FIG. 13A, and FIG. 13D shows a cross - sectional view of the metal coupon 200 of FIGS. 13A - B at the coupon opening 204 as observed along the line of sight 13D - 13D of FIG. 13A. FIGS. 15A - B show two top - down views of the metal coupon within the component according to embodiments of the disclosure.

[0064] As shown in FIGS. 7A - D, the metal coupon 200 may have a first porous region 300 having a first porosity. In FIGS. 7A - D, the metal coupon 200 includes a single porous region 300 having a single first porosity. In FIGS. 7A - D, the entire metal coupon 200 includes the first porosity. Thus, each layer of the metal coupon 200 has the same porosity (not solid). In FIGS. 10A - C and FIGS. 11A - C, the metal coupon 200 may include two porosity sub - regions 314A - B having different porosities. In FIGS. 10A - C, the two different porous sub - regions 314A, 314B are formed in a layered manner in an inner and outer region where one is further inside than the other. In FIGS. 11A - C, the two different porous sub - regions 314A, 314B are on different sides of the metal coupon 200. The regions within the layer of the metal coupon 200 that define the sub - regions 314A - B can be formed to include pores 302. In FIGS. 9A - C, the metal coupon 200 includes one or more porous sub - regions 314C, each of which may have the same or different porosities and has a solid region 304. The regions within the layer of the metal coupon 200 that define the sub - regions 314A - B can be formed to include pores 302, and the regions within the layer of the metal coupon 200 that define the solid region 304 are formed without pores 302. In FIGS. 10A - C, the metal coupon 200 includes a variable porosity sub - region 314D (possibly including a part thereof) between the first porous sub - region 314A and the second porous sub - region 314B. The regions within the layer of the metal coupon 200 that define the sub - regions 314A - B or the variable porosity sub - region 314D can be formed to include pores 302 of different sizes or numbers, creating different porosities. The variable porosity sub - region 314D may have any changing porosity, for example, increasing, decreasing, and / or any porosity where both increase and decrease. The change in porosity can change gradually, step - by - step, or otherwise progressively.The variable porosity sub-region 314D is shown in FIGS. 10A - C between the internal and external porosity sub-regions 314A, 314B, but the variable porous region can also be applied to the FIGS. 11A - C version. Each porous region 300 may have a void space volume of 2 - 50% relative to the total volume of the porous region 300, i.e., a porosity between 50 - 98% solid and 2 - 50% void space. In other embodiments, each porosity may be a void space volume of 10% - 40% relative to the total volume of the porous region 300, i.e., 10% - 40% void space and 60 - 90% solid for the rest. Other ranges of porosity are possible. For example, the porous region 300 can have any porosity described herein.

[0065] The anchor 294 can take various forms to position, align, and / or hold the metal coupon 200 in the coupon opening 204 of the body 206 of the component 202. More specifically, the anchor 294 can include a first section 292 of various shapes on or in the metal coupon 200 configured to interact with a second section 296 of complementary shape in or on the coupon opening 204 of the body 206 of the component 202. In FIGS. 7A - C, FIGS. 8A - C, FIGS. 9A - C, FIGS. 11A - C, and FIGS. 13A - D, the first section 292 is an elongated protrusion and the second section 296 is a complementary elongated opening that receives the first section 292. The first section 292 in the form of an elongated protrusion can be any of the following. As shown in FIGS. 7A - C, a complementary female dovetail or trapezoidal male dovetail or trapezoidal second section 296 within the body 206, a polygonal shape (other than a dovetail shape) having a polygonal opening second section 296 complementary to the body 206 as shown in FIGS. 11A - C, and a curved or semi - circular shape having a curved or semi - cylindrical opening second section 296 complementary to the body 206 as shown in FIGS. 8A - C, FIGS. 9A - C, and FIGS. 13A - D. Regarding the polygonal shape in FIGS. 11A - C, a three - sided protrusion is shown with relatively equal lengths, while other polygonal shapes such as triangles, pentagons, etc. are also possible. However, in most cases, it is advantageous to have an anchor 294 with a rounded or gradually changing surface to reduce stress. However, this is not required in all cases.

[0066] In some embodiments, the elongated protrusion includes a plurality of elongated protrusions. In some cases, as shown in FIGS. 8A - C, FIGS. 11A - C, and FIGS. 13A - D, the elongated protrusions are on the opposite side of the metal coupon 200. In other cases, as shown in FIGS. 9A - C, the elongated protrusions are on the same side of the metal coupon 200. For example, as shown in FIGS. 9A - C, the plurality of elongated protrusions may include a plurality of cylindrical pegs or rods extending from the metal coupon 200 that sits within a complementary opening, i.e., the second section 296, and extending into the body 206 from the coupon opening 204 of the body 206.

[0067] The elongated protrusion may at least partially or extend partially along the side surface of the AM metal member 290. More specifically, the first section 292 in the form of the elongated protrusion can extend along the side surface of the AM member 290 in any way that enables alignment with the second section 296 in the form of a complementary elongated opening in the body 206 of the component 202. In FIGS. 7A-D, FIGS. 8A-C, and FIGS. 11A-C, the elongated protrusion extends along the entire AM metal member 290. In FIGS. 7A-D and FIGS. 11A-C, the elongated protrusion runs perpendicular (as shown in the figures) along the entire side surface of the AM member 290. In FIGS. 8A-C, the elongated protrusion runs horizontally or longitudinally (as shown in the figures) along the side surface of the AM member 290. In FIGS. 13A-D, the elongated protrusion runs perpendicular (as shown in the figures) only along a part of the side surface of the AM member 290. The embodiment of FIGS. 13A-D may advantageously position the metal coupon 200 in a positive position in the coupon opening 204 of the body 206, as shown in FIG. 13D, and includes a second section 296 (vertically as shown in FIG. 13D) in the coupon opening 204 that restricts the advancement of the metal coupon through the coupon opening 204. In FIGS. 13A-D, the first section 292 is formed only partially across the surface of the metal coupon 200 so as to act as a stop that restricts further movement of the metal coupon 200. For example, if the first section 292 is formed on the positive pressure side (near-side outer walls 152, 178 or side 326) of the metal coupon 200, the pressure applied during operation of the component 202 helps to hold the metal coupon 200 in a predetermined position to prevent the metal coupon 200 from moving further to the negative pressure side (side outer walls 154, 180 or side 328).

[0068] In other embodiments, as shown in FIGS. 7D, 10A - C, and 12A - D, the first section 292 of the anchor 294 may include an elongated opening such as a slot. The first section 292 in the form of an elongated opening can be any of the following. As shown in FIG. 7D, a complementary male dovetail or trapezoidal - shaped second section 296 within the body 206, a curved or semi - cylindrical shape having a complementary curved or semi - cylindrical protrusion second section 296 within the body 206 as shown in FIGS. 10A - C, and a polygonal shape (other than a dovetail shape) having a polygonal protrusion 296 complementary to the body 206 as shown in FIGS. 12A - D. Regarding the polygonal shape of FIGS. 12A - D, while the three - sided opening is shown with relatively equal lengths, other polygonal shapes, such as triangles, pentagons, etc., are also possible. In most cases, it is advantageous for the surface of the anchor 294 to be rounded or to change gradually in order to reduce stress. However, this is not required in all cases.

[0069] In some embodiments, the slot includes a plurality of slots. In some cases, as shown in FIGS. 10A - C and 12A - D, the elongated opening is on the opposite side of the metal coupon 200. In other cases, as shown in FIG. 7D, the elongated opening (one is shown for clarity) can be on the same side of the metal coupon 200.

[0070] The elongated opening may at least partially or extend partially along the side surface of the AM metal member 290. More specifically, the first section 292 in the form of the elongated opening can extend along the side surface of the AM member 290 in any way that allows alignment with the second section 296 in the form of a complementary elongated protrusion in the body 206 of the component 202. In FIGS. 10A - C, the elongated opening extends along the entire AM metal member 290. In FIGS. 12A - D, the elongated opening runs vertically (as shown in the figure) only along a part of the side surface of the AM member 290. The embodiment of FIGS. 12A - D advantageously uses a second section 296 that includes a complementary seat within the coupon opening 204 that restricts the advancement of the metal coupon in the coupon opening 204 to position the metal coupon 200 in the correct position in the coupon opening 204 of the body 206 (vertically as shown in FIG. 13D). More specifically, referring to FIGS. 3, 4, 12A, and 13A, a configuration using a first section 292 that extends only partially along the side surface of the AM member 290 can be advantageous in providing more resistance to movement due to forces from the first positive pressure side 326 of the airfoils 150, 176 compared to the second negative pressure side 328 of the airfoils 150, 176.

[0071] In either of the aforementioned versions of the metal coupon 200 and the anchor 294, sections 292, 296 may include angled, wedge-shaped, or mating surfaces that position the metal coupon 200 in a desired location and prevent the metal coupon 200 from further passing through the coupon opening 204 of the body 206. For example, with respect to the embodiments of FIGS. 7A - D, FIGS. 10A - C, and FIGS. 11A - C, the joining surfaces of sections 292, 296 may be angled in a way that the first section 292 cannot pass through, i.e., slide through, and the second section 296 cannot pass through. FIG. 14 shows a cross-sectional view of the anchor 294 along line of sight X - X of FIGS. 7C - D, FIG. 10C, and FIG. 11C, and in an alternative embodiment, sections 292, 296 have angled (wedge-shaped) surfaces that prevent passage from the first section 292 to the second section 296. The upper end of the protrusion of section 292 is wider than its lower end, and the upper end of the opening of section 296 is wider than its lower end. Any form of angled, wedge-shaped, or other movement-restricting mating surfaces of sections 292, 296 can be used in the aforementioned embodiments. The embodiments of FIGS. 12A - D and FIGS. 13A - D do not need to prevent additional movement for one of sections 292, 296, but angled, wedge-shaped, or other movement-restricting mating surfaces such as in FIG. 14 can also be applied to those embodiments (and the embodiments of FIGS. 8A - C and FIGS. 9A - C).

[0072] Figures 15A - B show an embodiment in which both the first section 292 of the metal coupon 200 and the second section 296 of the body 206 of the component 202 include recesses, and a locking element 298 is engaged to lock the sections 292, 296 together. More specifically, the first section 292 and the second section 296 each have a recess, and the anchor 294 further includes a locking element 298 configured to engage the recess of the first section 292 and the recess of the second section 296, and cooperatively hold the AM metal coupon 200 in the coupon opening 204 of the body 206. In FIG. 15A, the recesses are curved, for example, semi - circular or semi - cylindrical, and the locking element 298 has a shape complementary to the collective shape of the recesses, for example, circular or cylindrical. In FIG. 15B, the recesses are polygonal, for example, semi - square, and the locking element 298 has a shape complementary to the collective polygonal shape of the recesses, for example, square. It is recognized that the sections 292, 296 and the locking element 298 can have various alternative shapes and forms. The recesses of the locking element 298 and the sections 292, 296 may have any depth, inside or outside the pages of FIGS. 15A - B. The ends of the locking element 298 may be configured (e.g., constructed or machined) to be in the same plane as the outer surface of the metal coupon 200 and the body 206 of the component 202.

[0073] Although various numbers and positions of the sections 292, 296 for the anchor 294 are shown, it is recognized that the number and position of the anchors of the sections may be different from those shown. For example, the anchor 294 can be placed on any side of the metal coupon 200. If multiple anchors 294 are used, they need not be opposite each other on the metal coupon 200, for example, see FIGS. 16A - B. Further, although specific exemplary embodiments are described, the various embodiments can be selectively used together in any manner.

[0074] Referring to FIGS. 3, 4, 7A-14B, and 17A-F, embodiments of the method according to the disclosure will now be described. The method may include, for example, coupling a metal coupon to component 202 to repair component 202. FIGS. 16A-F show perspective views of the method according to embodiments of the disclosure.

[0075] FIG. 16A shows a coupon opening 204 created in the body 206 of component 202. Coupon opening 204 is configured to receive metal coupon 200. Coupon opening 204 may have any shape. In certain applications, coupon opening 204 is created by removing a damaged portion of body 206 of component 202, but coupon opening 204 may also be in an area of the original version of component 202, for example, a location where it is difficult to manufacture the remaining portion of component 202. In the non-limiting example shown, coupon opening 204 is at the trailing edge 184 of nozzle 126. Coupon opening 204 can be created using any form of second section 296 for anchor 294, as described herein. An example similar to that of FIGS. 13A-C is shown in FIG. 16A. (Note, FIGS. 16B-F do not show the first section 292 and second section 296 of anchor 294 for clarity. Coupon opening 204 including second section 296 can be formed in existing component 202 using any metalworking technique known currently or developed in the future, such as cutting, drilling, grinding, electrical discharge machining, etc. In the case of a new product, coupon opening 204 with second section 296 can be formed, for example, by casting, additive manufacturing, etc. FIG. 16A also shows creating a model of coupon opening 204 as appropriate. Model creation may include using any 3D scanner (not shown, see arrow) known currently or developed in the future to scan a digitized representation of coupon opening 204 relative to body 206 of component 202. Since the process of scanning and modeling components is well known in the art, further details are omitted so that the reader can focus on the salient aspects of the disclosure.

[0076] Figures 5, 7A - 14B show a laminated metal coupon 200 having a porous region 300 with a noted porosity, and a first section 292 of an anchor 294. The metal coupon 200 can be laminated using any version of the porous region / sub - region and anchor 294 described herein. For example, FIG. 7A also shows a formed metal coupon 200 having a single porosity (non - solid), and FIG. 10A also shows a formed metal coupon 200 having a variable porosity sub - region 314D between a first porous sub - region 314A and a second porosity sub - region 314B and possibly including a portion of the second porous sub - region 314B. The variable porosity sub - region 314D may include a porosity that gradually changes from the porosity of the first porous sub - region 314A to the porosity of the second porosity sub - region 314B. As described above, the change in porosity can be gradual, step - wise, or progressive. The first, second, and variable porosity sub - regions differ from each other in at least one aspect of the ratio of void space volume to total volume, pore shape, pore size, number of pores, and characteristics of pore connection passages. The lamination may include any AM process described herein for manufacturing the porous metal coupon 200 (or a dense or solid region). The lamination may include selectively forming the porous region 300 within the solid region of the metal coupon 200 by controlling an AM printer 232. The lamination may include manufacturing a metal coupon 200 having a near - net shape of the second section 296 of the anchor 294 generally aligned with or based on the model of the coupon opening 204. As used herein, "near - net shape" indicates that the metal coupon 200 is within the desired manufacturing tolerances and that at a specified stage of the manufacturing process, additional processing such as machining is either none or minimal. Additional texturing or polishing of the exterior surface may be desirable. It is recognized that an additional coating may be applied when the metal coupon 200 is placed within a component.When the metal coupon 200 is formed in a substantially net shape, after manufacturing, when it is located at the coupon opening 204, it has a shape very close to the surface of the body 206 necessary to bond the metal coupon 200 within the coupon opening 204, for example, a selected brazing material and whether there is no necessary finishing method such as machining or grinding, or it can also have a minimally required shape. However, the use of the porous region 300 in the metal coupon 200 accommodates larger joint gap dimension variations compared to a solid coupon with a narrow gap for the brazing material, as the porous region improves the brazing material's grip and retention despite the larger gap. The anchor 294 assists in the placement, alignment, and / or retention of the metal coupon relative to the coupon opening of the component body. The metal coupon 200 is additive manufactured as in the embodiment of FIG. 8A in FIGS. 16B - C, but may take any form described herein. It is recognized that while a particular arrangement is shown, the first and second sections 292, 296 can be interchanged in position. That is, the first section 292 can be placed either in or on either the metal coupon 200 or the coupon opening 204 of the body 206 of the component 202, and the second section 296 can be placed either in or on the other of the metal coupon 200 and the coupon opening 204 of the body 206 of the component 202.

[0077] According to embodiments of the present disclosure, the porosity of the porous region 300 and / or the porous region 314 of one or more porosity partial regions 314 within the metal coupon 200 is controlled, i.e., customized, during a subsequent brazing process of joining the metal coupon 200 to control the flow of the brazing material therein, as shown in FIGS. 3, 4, and 16D - F, the coupon opening 204 in the body 206 of the component 202. The porous region 300 and each partial region 314 may be customized from the perspective of any of the aforementioned properties that affect porosity. Further, the shape and / or position of the porous region 300 and / or the partial region 314 can be arranged to direct brazing of the material as desired. For example, in FIG. 7A, the entire metal coupon 200 includes a single porosity, and the porous region 300 is configured such that the brazing material is uniformly distributed therein. In contrast, in FIG. 8A, the metal coupon 200 includes one porous partial region 314A near the edge 306 of the metal coupon 200, where it joins the coupon opening 204 (FIGS. 3 - 4), and a different porosity partial region 314B having a different porosity adjacent to the first porous partial region 314A, e.g., joining distally from the edge 306. In this way, the brazing material 310 will be distributed in different ways in each porous partial region 314, and as a result, different physical properties of the metal coupon 200 in its different partial regions will occur. More specifically, any number of porous partial regions 314 can be used to customize (create) at least one physical property of the component 202 including the metal coupon 200, e.g., joint adhesive bond strength, coupon strength, stress / strain resistance, ductility, wear resistance, oxidation resistance, cyclic fatigue, thermal conductivity, electrical conductivity, surface roughness, hardness, and mass. In a non - exhaustive list of possibilities, the metal coupon 200 may include a higher porosity in one partial region 314 to induce more brazing material therein by capillary action compared to other solid regions of the metal coupon 200, to control at least one physical property of the component 202.In another embodiment, the metal coupon 200 may include a lower porosity in one partial region 314 to reduce the solder material therein by capillary action and control at least one physical property of the component 202, as compared to other solid regions of the metal coupon 200. In other embodiments, the metal coupon 200 may include two or more porous regions 300 or porous partial regions 314 within the porous region 300 that collectively constitute the entire metal coupon 200. Any arrangement of the porous region 300 or partial region 314 can create a desired solder flow and infiltration.

[0078] In one embodiment, additive manufacturing may also include forming any of a variety of improvements to the component 202 in the metal coupon 200, for example, including structures that did not previously exist in the removed damaged component. For example, as shown in FIG. 16C, additive manufacturing may optionally include forming cooling passages 320 in the metal coupon 200. The cooling passages 320 can extend through the metal coupon 200 in any manner, for example, in a serpentine path therein or through the outer surface 322 of the metal coupon 200. Any advantageous internal structural modifications can be made to the metal coupon 200. Post-additive manufacturing finishing operations that are currently known or developed in the future may be optionally performed on the metal coupon 200, for example, polishing its smooth surface. Advantageously, however, the teachings of the present disclosure may eliminate the need for other finishing steps commonly used to address residual stresses present in the material after additive manufacturing, such as peening, heat treatment, hot isostatic pressing (HIP).

[0079] Figures 16B and 16C show the placement metal coupon 200 in the coupon opening 204 of the body 206 of the component 202. The metal coupon 200 can be placed in the coupon opening 204 of the body 206 by any method known currently or developed in the future, for example, using a robotic arm or manually. As described herein, the anchor 294 holds the metal coupon 200 in the coupon opening 204. More specifically, the anchor 294 acts to place, align, and / or hold the metal coupon 200 in the coupon opening 204 of the body 206. The metal coupon 200 can be inserted into the coupon opening 204 in any direction required by the anchor 294. For example, as shown in FIGS. 16B - C, the metal coupon 200 may be inserted from the first side surface 326 to the second side surface 328 of the component 202. In other cases, for example, as in the embodiments of FIGS. 8A - C, the metal coupon 200 may slide longitudinally into the coupon opening 204. Any technique necessary to temporarily hold the metal coupon 200 in a predetermined position beyond what is already provided by the anchor 294 may be used, for example, using an adhesive tape.

[0080] Figures 16D - E show impregnating the metal coupon 200 with the brazing material 310 to bond the metal coupon 200 to the coupon opening 204 of the body 206, that is, the brazing process. The brazing material 310 may include any brazing composition known currently or developed in the future (for example, but not limited to, GE (Alstom) B1P, Amdry™ D15, DF4B, or BRB, etc.), and a part of its composition is shown in the following table together with other brazing material compositions.

[0081] [Table 1]

[0082] Infiltration can include any currently known or future developed brazing process (such as the use of vacuum brazing systems, induction brazing systems, and / or inert gas atmosphere heating systems and related technologies). In one non-limiting example, brazing may include, for example, applying a brazing material (Figure 8D) and heating (Figure 8E), and allowing it to flow into and around the metal coupon 200 by capillary action.

[0083] Infiltration involves injecting the brazing material 310 into the porous region 300 based on the characteristics of its first porosity, for example, injecting it into a first porosity partial region 314A and at least a second porosity partial region 314B based on at least the characteristics of the first porosity. If there is a variable porosity partial region 314D (Figure 10A), infiltration includes moving the brazing material 310, infiltrating through the first porosity partial region 314A based on the characteristics of the first porosity, moving and infiltrating through the variable porosity partial region 314D based on the characteristics of the variable porosity partial region 314D (such as, for example, a porosity gradient, stepped porosity, especially), moving through the second porosity partial region 314B, and infiltrating based on the characteristics of the second porosity.

[0084] The different porosities of the porous partial regions 314A, 314B, and perhaps the variable porosity partial region 314D result in different flows and infiltrations of the filler 310. As a result of the brazing process, the first porous partial region 314A and the second porous partial region 314B, and the filler 310 therein have at least one different physical property. If the variable porosity partial region 314D exists, it probably has physical properties different from those of the first and second porosity partial regions 314A, 314B. Thus, as a result of the brazing process, the first porous partial region 314A and the second porous partial region 314B (and perhaps the variable porosity partial region 314D) have at least one different physical property when the filler 310 is included in the component 202 therein. For example, when there is more filler 310, the joint adhesion strength may increase, the ductility may increase, the thermal conductivity or electrical conductivity may increase, and the oxidation resistance may increase. When there is less filler 310, the surface roughness may decrease, the hardness may decrease, the ductility may increase, the joint adhesion strength may decrease, the thermal conductivity or electrical conductivity may decrease, or the oxidation resistance may decrease. In any case, by controlling the amount of the filler and the porosity of the different porous regions / partial regions, the physical properties of the final product can be controlled. In one example, the first porosity of the first porous partial region 314A may be higher (i.e., lower density) than the second porosity of the second porous partial region 314B. In this case, the infiltration includes infiltrating more filler 310 into the first porous partial region 314A than into the second porous partial region 314B. Depending on the filler 310 used, among other factors, the different porosities enable the customization of at least one physical property of the component 202, such as, for example, joint adhesive strength, stress / strain resistance, ductility, wear resistance, oxidation resistance, thermal conductivity, electrical conductivity, surface roughness, hardness, and / or mass. Furthermore, the multi-flow path of the filler 310 using the porous region 300 may reduce the possibility of insufficient filling and / or voids along the brazed joint compared to conventional narrow gap filling brazing processes and due to the strict manufacturing tolerances required for narrow gap brazing.Thus, component 202 can be at least 98% solid, despite the use of metal coupon 200 having a porous region 300 therein. Anchor 294 can assist in the placement, alignment and / or retention of metal coupon 200 relative to coupon opening 204 of body 206 of component 202 and can form part of any joint.

[0085] In certain embodiments, different solders 310 are used on different portions of metal coupon 200 to provide further customization of the bonding of metal coupon 200 in component 202 and the physical properties of regions of component 202. For example, referring to FIGS. 17C and 17D, a first solder 310A may be used on a first component or side 326 of component 202, and a different solder 310B may be used on a different component or side 328 of component 202 that is different from first solder 310A. In one example, referring to FIGS. 3, 4, and 17C, the first component or side 326 of component 202 may be the first (concave positive pressure) side outer walls 152, 178 of airfoil portions 150, 176, and the second or side 328 of component 202 may be the second (convex negative pressure) side outer walls 154, 180 of airfoil 150. In addition to different porous partial regions 314 on different components or sides 326, 328, different solders 310A, 310B can be customized according to the expected environment of component 202 at their locations. Although it will be apparent, the possible variations in solders and / or porous regions are innumerable to address various situations.

[0086] Other embodiments of the method according to the present disclosure may only include forming the metal coupon 200 for the component 202. In this case, as shown in FIG. 16A, the method creates a model of the coupon opening 204 in the body 206 of the component 202 and additive manufactures the metal coupon 200 to closely fit at least the coupon opening 204, for example, having a near-net shape of the coupon opening 204. As described herein, for example, as shown in FIGS. 8A, 10A, and 11A, the metal coupon 200 may include at least a first porosity partial region 314A having a first porosity and a second porosity partial region 314B different from the first porosity. The metal coupon 200 may also include any first section 292 of the anchor 294 described herein. The different first and second porosities result in different physical properties after bonding the metal coupon 200 to the coupon opening 204 using the brazing material 310.

[0087] FIG. 16F illustrates, but is not limited to, any finishing steps of the component 202, such as machining to smooth the exterior surface and remove excess brazing material. As described above, the teachings of the present disclosure eliminate the need for other finishing processes, such as peening, heat treatment, hot isostatic pressing (HIP), etc.

[0088] Figures 3, 4, and 17A - D illustrate embodiments of component 202 according to the disclosed embodiments, and FIGS. 17A - D show enlarged cross-sectional views of metal coupon 200 on coupon opening 204 of body 206 of component 202. FIG. 17A shows component 202 having metal coupon 200 with a single porous region 300, FIG. 17B shows component 202 having metal coupon 200 with two or more porous partial regions 314A, 314B, FIG. 17C shows component 202 having metal coupon 200 with two or more layered porous partial regions 314A, 314B and different brazing materials 310A, 310B, and FIG. 17D shows component 202 having metal coupon 200 with two porous partial regions 314A, 314B on different sides 326, 328 of metal coupon 200 and different sides 314A, 314B of different brazing materials 310A, 310B.

[0089] Component 202 includes a body 206 having a coupon opening 204 therein. As described herein, body 206 can have any form for a particular industrial application in which component 202 is used. In the examples used herein, body 206 may include a turbine rotating blade 132 (FIG. 3) or a turbine stationary nozzle 126 (FIG. 4).

[0090] Component 202 also includes an additive manufacturing (AM) metal coupon 200. The metal coupon 200 is shown, for example, in the airfoil portions 150, 176 of the blades 132 and nozzles 126 of FIGS. 3 and 4, but the metal coupon 200 can be present in any part of the body 206 of the component 202. The metal coupon 200 has a porous region 300 having a porosity between 2% and 50% void space volume relative to the total volume of the porous region. Other porosities as described herein are also possible. The component 202 may also include an anchor 294 that includes one or more of the sections 292, 296 on one or above the AM metal coupon 200 and the body 206, and the sections 292, 296 on the other or above the AM metal coupon 200 and the body 206. At least the sections 292, 296 cooperate to hold the AM metal coupon 200 in the coupon openings 204 of the body 206. The anchor 294 is shown in the form of the embodiments of FIGS. 13A - D in FIG. 17A, or otherwise shown as a dashed line as one of the embodiments of FIGS. 10A - C or FIGS. 11A - C in FIGS. 17B - D. Any of the anchors 294 described herein can be used. For example, as shown in FIGS. 7A - D, FIGS. 8A - C, FIGS. 9A - C, FIGS. 11A - C, FIGS. 12A - D, and FIGS. 13A - D, the first section 292 of the anchor 294 may be an elongated protrusion, and the second section 296 of the anchor 294 may be an elongated opening configured to receive the elongated protrusion of the first section 292. The elongated protrusion and the elongated opening may complement any of a male - female dovetail shape (FIGS. 7A - D), a male - female polygonal shape (FIGS. 11A - C, FIGS. 12A - D), or a male - female curved shape (FIGS. 8A - C, FIGS. 9A - C, FIGS. 10A - C, and FIGS. 13A - D). The elongated protrusions may include a plurality of elongated protrusions, and the elongated openings may include a plurality of elongated openings configured such that each opening receives each respective elongated protrusion. As shown in FIGS. 12A, 12D, 13A, and 13D, the first section 292 extends at least in part or partially along a first distance D1 on one side of the AM metal coupon 200 (shown) and the body 206, and the second section 296 may extend along a second distance D2 on the other side of the AM metal coupon 200 and the body 206.In summary, the first and second distances D1 and D2 are the same dimension as the thickness T of the coupon opening 204. The first and second distances D1 and D2 may be equal.

[0091] Regarding the porous region 300, the porous region may further include at least a first porosity partial region 314 having a first porosity, as described herein in connection with FIGS. 8A - C, FIGS. 9A - C, FIGS. 10A - C, and FIGS. 11A - C. The component 202 includes a brazing material 310 of the metal coupon 200 connected to the coupon opening 204 of the main body 206. The brazing material 310 infiltrates the porous region 300 (and any partial region 314) at least based on its porosity characteristics. As shown in FIG. 17A, the brazing material 310 includes a first section 330 that infiltrates the first porous partial region 314A based on at least the characteristics of the first porosity. As shown in FIGS. 17B and 17D, the metal coupon 200 may further include one or more second porosity partial regions 314B having a second porosity different from the first porosity. The first porosity may be different from the second porosity in terms of at least one characteristic of the ratio of void space volume to total volume, void shape, pore size, number of pores, and pore connection passages. The main body 206 may have a third porosity different from both the first and second porosities. For example, the main body 206 can have a third porosity with a higher density than both the first and second porosities and can be, for example, 100% solid. Optionally, the metal coupon 200 may include a variable porosity partial region 314D (shown by the dashed box in FIG. 17B) between (and possibly including a part of) the first porosity partial region 314A and the second porosity partial region 314B. The variable porosity partial region 314D may gradually change the porosity, for example, step - by - step or progressively, between the first and second porosities. In FIG. 17B, the different porous partial regions 314A, 314B are layered one inside the other in the metal coupon 200. In FIG. 17D, the different porous partial regions 314A, 314B are on opposite sides of the metal coupon 200 (as in the embodiments of FIGS. 11A - C).

[0092] In FIG. 17B, the brazing material 310B includes a second section 332 that infiltrates into the second porous partial region 314B based on at least the characteristics of the second porosity. The “characteristics” of the porosity indicate that the porosity can bring about various infiltration characteristics such as brazing material volume, pattern within the porosity, crystallization, etc. However, as is apparent in the art, other factors can also affect the infiltration characteristics (such as the type of brazing material) as well as the characteristics of the brazing process (temperature, pressure, position of the component 202 and / or format and arrangement of the metal coupon 200, etc.). The results of different porosities are that the first porous partial region 314A and the second porous partial region 314B having the brazing material 310 therein have one or more different physical characteristics. The porosity can be customized to select their physical characteristics as long as the porosity can affect their physical characteristics. In one example, the first porosity of the first porous partial region 314A may be higher (i.e., lower density) than the second porosity of the second porous partial region 314B, and the first porous partial region 314A contains more brazing material 310 inside than the second porous partial region 314B. In another example, the first porous partial region 314A shown in FIG. 17B is at least partially on the edge 306 of the metal coupon 200 configured to join to the body 206, and the second porous partial region 314B is on the inner back side of the metal coupon 200. In another example, as shown in FIG. 17D, the first porous partial region 314A is on one edge 326 of the metal coupon 200, and the second porous partial region 314B is on the opposite side 328 of the metal coupon 200. Thus, different sides of the metal coupon 200 and the component 202 can have different physical characteristics. Regarding the airfoil portions 150, 176 of the nozzle 126 or the blade 132, as shown in FIGS. 3 and 4, the positive-pressure side outer walls 152, 178 of the airfoil portions may each have different physical characteristics from the negative-pressure side outer walls 154, 180 of the airfoil portions. In any case, the second porous partial region 314B may be adjacent to the first porous partial region 314A.Alternatively, the second porous sub-region 314B may be adjacent to at least (another) portion of the edge 306 of the metal coupon 200 and may perhaps be adjacent to the first porous sub-region 314A. This arrangement may be advantageous for increasing the amount of brazing material 310 disposed near the brazed joint 334, as shown in FIG. 17B, for improving the joint hermeticity strength of the metal coupon 200, reducing oxidation at the brazed joint 334, or reducing the thermal conductivity of the brazed joint 334. Any of the physical properties described herein can also be customized based on different porosities and / or different brazing materials. As described above, depending on the brazing material 310 used, differences in porosity allow the physical properties of the component 202 (e.g., joint adhesive bond strength, stress / strain resistance, ductility, wear resistance, oxidation resistance, thermal conductivity, electrical conductivity, surface roughness, hardness, and / or mass) to be customized.

[0093] In FIG. 17D, the brazing material 310B also includes a second section 332 that infiltrates into the second porous partial region 314B based at least on the characteristics of the second porosity. In the example of FIG. 17D, the first porous partial region 314A is at the edge 326 of the metal coupon 200, and the second porous partial region 314B is at the opposite side 328 of the metal coupon 200. Thus, different sides of the metal coupon 200 and the component 202 may have different physical characteristics. Regarding the airfoils 150, 176 of the nozzle 126 or the blade 132, as shown in FIGS. 3 and 4, the positive-pressure side outer walls 152, 178 of the airfoils may each have different physical characteristics from the negative-pressure side outer walls 154, 180 of the airfoils. In any case, the second porous partial region 314B may be adjacent to the first porous partial region 314A. This arrangement may be advantageous for placing more brazing material 310 closer to the brazed joint 334 on the side 326 to enhance the bonding strength of the brazed joint of the metal coupon 200, as shown in FIG. 17D, or to reduce oxidation at the brazed joint 334, or to increase the thermal conductivity at the brazed joint 334. Any of the physical characteristics described herein can also be customized based on different porosities and / or different brazing materials. As described above, depending on the brazing material 310 used, differences in porosity enable customization of the physical characteristics of the component 202 (e.g., joint adhesive bonding strength, stress / strain resistance, ductility, wear resistance, oxidation resistance, thermal conductivity, electrical conductivity, surface roughness, hardness, and / or mass).

[0094] In any of FIGS. 17A-17D, the anchor 294 assists in the placement, alignment, and / or retention of the metal coupon 200 relative to the coupon opening 204 in the body 206 of the component 202. The brazing material 310 infiltrates around and / or into the anchor 294, and the anchor 294 also includes a porous region 300.

[0095] As described above, the metal coupon 200 may have a near-net shape of the coupon opening 204 in the body 206 of the component 202. As shown in FIG. 16C, the metal coupon 200 may optionally include a cooling passage 320 therein. One or more cooling passages may be defined in the metal coupon 200 and penetrate the outer surface 322 of the metal coupon.

[0096] In the present application, specific positions are exemplified for various porous regions 300 or partial regions 314, but the various porous regions may be arranged in any manner because they provide the component 202 with various brazing material infiltration characteristics and various physical characteristics.

[0097] Embodiments of the present disclosure may also include, as shown in FIGS. 1-2, a turbomachine 100 (e.g., a turbine assembly 110) 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 126, a turbine rotating blade 132, or other components of the turbomachine 100. The metal coupon 200 can be used for new or repaired components.

[0098] The present disclosure provides various technical and commercial advantages, examples of which are described. With respect to component repair, in additive manufacturing, custom-fit shaped metal coupons can be cost-effectively created, and only the damaged material needs to be removed. The porous region can increase the proportion of the base metal alloy in a specific region (e.g., >60%), and improved physical properties may be obtained compared to, for example, a pre-sintered preform. The porous region can also result in a brazing / fusion particle matrix (e.g., a superalloy metal base material) with enhanced brazing filler compared to metal particles surrounded by a brazing filler as in the conventional manner. The multiple flow paths for the brazing filler using the porous region can reduce the risk of underfilling and / or void generation along the brazed joint compared to the conventional brazing process that fills a narrow gap. The porous region can be formed with various porosities throughout the metal coupon, enabling highly customized brazing filler flow. The porous region can also accommodate a large variation in joint void dimensions compared to a solid coupon during machining where the gap for the brazing filler is narrow. Repairs utilizing the teachings of the present disclosure are stronger than conventional narrow-gap brazing processes, do not require specific post-repair finishing, and have improved physical properties compared to current technologies such as pre-sintered preforms (PSP). The anchor assists in the placement, alignment, and / or retention of the metal coupon relative to the coupon opening in the component body and mechanical retention during component operation.

[0099] The approximate expressions used in this specification and the claims are quantitative modifiers applied to indicate quantities that can vary within an acceptable range that does not cause a change in the basic function to which the quantity relates. Thus, values modified by terms such as "about," "substantially," and "essentially" are not limited to their exact numerical values. In some instances, the approximate expression corresponds to the precision of the instrument used to measure the value. In some cases, the approximate expression corresponds to the precision of the instrument used to measure the value. In this specification and the claims, ranges of numerical limitations are combinable and / or interchangeable with each other. Such ranges specify and subsume any sub-ranges included within the range, unless otherwise apparent from the context. The "about" used for a particular value of a range applies to the upper and lower limits and may indicate ±10% of the recited numerical value, except when it depends on the precision of the instrument used to measure the value.

[0100] In the following claims, corresponding structures, materials, acts, and equivalents of the components specified by functional recitation include any structure, material, or act that functions in combination with other components specifically recited in the claims. The description of the present disclosure is for purposes of illustration and explanation and is neither exhaustive nor limiting to the disclosed forms. Numerous modifications and variations will be apparent to those skilled in the art without departing from the technical scope and technical idea of the present disclosure. Embodiments of the present disclosure are selected and described to best explain the principles of the present disclosure and its practical applications and to enable those skilled in the art to understand the present disclosure regarding various embodiments and various modifications suitable for specific uses.

Description of Reference Numerals

[0101] 200 Metal coupon 202 Component 204 Coupon opening 206 Body of the component 290 Additively manufactured metal member 292 First section of the anchor 294 Anchor 300 Porous region 310 Solder

Claims

1. A metal coupon (200), comprising:

1. An additively manufactured (AM) metal component (290), comprising: a porous region (300) having a void space volume of 2 to 50% of the total volume of the porous region (300); a first section (292) of an anchor (294) configured to interact with a complementarily shaped second section (296) of the anchor (294) of a body (206) of a part (202) to which the metal coupon (200) is bonded; A metal coupon (200) comprising an additively manufactured metal part (290) comprising:

2. The metal coupon (200) of claim 1, wherein the first section (292) of the anchor (294) is an elongated projection.

3. The metal coupon (200) of claim 2, wherein the elongated projection has one of a male dovetail shape, a polygonal shape, and a curved shape.

4. The metal coupon (200) of claim 2, wherein the elongated projection extends at least partially along a side of the additively manufactured metal part (290).

5. The metal coupon (200) of claim 2, wherein the elongated projection comprises a plurality of elongated projections.

6. The metal coupon (200) of claim 1, wherein the first section (292) of the anchor (294) is an elongated opening.

7. The metal coupon (200) of claim 6, wherein the elongated opening has one of a female dovetail shape, a polygonal shape, and a curved shape.

8. The metal coupon (200) of claim 6, wherein the elongated opening extends at least partially along a side of the additively manufactured metal part (290).

9. The metal coupon (200) of claim 1, wherein the first section (292) comprises at least a portion of the porous region (300).

10. A part (202), the part (202) comprising: a body (206) including a coupon opening (204); an additive manufacturing (AM) metal coupon (200) having a porous region (300) with a porosity of 2-50% void space volume relative to the total volume of the porous region (300); an anchor (294) including a first section (292) on one of the additively manufactured metal coupon (200) or the body (206) and a second section (296) on the other of the additively manufactured metal coupon (200) or the body (206), wherein at least the first section (292) and the second section (296) cooperate to hold the additively manufactured metal coupon (200) in a coupon opening of the body (206); a braze material for bonding the additively manufactured metal coupon (200) to the coupon opening of the body (206), the braze material infiltrating the porous region (300) based at least on the porosity characteristics; The part (202).

11. 11. The component (202) of claim 10, wherein the first section (292) of the anchor (294) is an elongated projection and the second section (296) of the anchor (294) is an elongated opening of a complementary shape to the elongated projection and configured to receive the elongated projection of the first section (292).

12. 12. The component (202) of claim 11, wherein the elongated projection and the elongated opening are either complementary male and female dovetail shapes, male and female polygon shapes, or male and female curved shapes.

13. The component (202) of claim 10, wherein the first section (292) comprises at least a portion of the porous region (300).

14. 11. The part (202) of claim 10, wherein a first section (292) extends a first distance along at least a portion of one side of the additively manufactured metal coupon (200) and the body (206) and a second section (296) extends a second distance along the other side of the additively manufactured metal coupon (200) and the body (206), the first distance and the second distance being equal.

15. 11. The component (202) of claim 10, wherein the first section (292) and the second section (296) each include a recess, and the anchor (294) further includes a locking element (298) configured to engage the recess of the first section (292) and the recess of the second section (296) to cooperatively retain the additively manufactured metal coupon (200) in the coupon opening (204) of the body (206).

Images