Abstract: A component includes a body having a coupon opening defined therein, and an additively manufactured (AM) metal coupon including a dense region, a porous region adjacent the dense region, and a coupon outer surface. The porous region has a first cross-sectional area at a first location at or near the coupon outer surface and a second cross-sectional area less than the first cross-sectional area at a second location distal from the coupon outer surface. A braze material couples the metal coupon in the coupon opening and infiltrates into the porous region, e.g., based at least on a characteristic of the porosity thereof. The dense region may have a third cross-sectional area at the first location and a fourth cross-sectional area greater than the third cross-sectional area at the second location so it can direct the braze material in the porous region toward an inner surface of the coupon opening.

Abstract: A component includes a dense base region, a dense replacement region and an additively manufactured (AM) porous region between the dense base region and the dense replacement region. The porous region has a porosity between 2% to 50% open space volume to total volume of the AM porous region. The porous region can be printed onto the base region or the replacement region. A braze material couples the base region, the porous region and the replacement region together, and infiltrates into the porous region based at least on a characteristic of the porosity. The porous region reduces stress at a joint between the dense regions and can be customized to create different physical characteristic(s) than just those of the base and replacement regions.

Abstract: A component including a body, and an additively manufactured (AM) metal coupon including a first section and a stress-relief section, is disclosed. The stress-relief section includes a porous region having a porosity between 2% to 50% open space volume to total volume of the stress-relief section. The stress-relief section has at least one of thermal conductivity, tensile strength, ductility, or fatigue strength less than first section. A braze material couples the AM metal coupon to a coupon opening in the body. The stress-relief section creates a low-stress zone in the metal coupon that can be located near or adjacent to a high-stress zone. The stress-relief section reduces residual stress in the metal coupon, which reduces the related challenges of coupling the metal coupon to the body of the component, especially where superalloy materials are used.

Abstract: A metal coupon includes an additively manufactured (AM) metal member having a porous region having between 2% to 50% open space volume to total volume. The metal coupon includes a first section of an anchor configured to interact with a second section of the anchor in a coupon opening of a body of a component. A component including the metal coupon may include the body including the coupon opening, and an anchor including a first section in or on one of the AM metal coupon and the body and a second section in or on the other of the AM metal coupon and the body. At least the first and second sections cooperatively hold the AM metal coupon in the coupon opening in the body. Braze material couples the coupon in the coupon opening in the body. The braze material infiltrates into the porous region.

Abstract: A metal coupon for repairing a component includes an additively manufactured (AM) metal member having a low porosity region in an interior of the AM metal member, and a porous region around the low porosity region. The low porosity region may have a porosity in a range of 0% to 5%, so is solid or nearly solid. The porous metal coupon with low porosity region allows braze material to be directed based on characteristics of the porous region.

Abstract: A component includes a body and an additively manufactured (AM) metal coupon that includes a primary member having a member porosity between 2% to 50% open space volume to total volume of the primary member. The primary member includes a first portion and a second portion distanced from the first portion by a gap. At least one thermal transfer structure, such as pin(s) and/or fin(s), extends between the first and second portions across the gap. A braze material couples the AM metal coupon in a coupon opening in the body, and infiltrates into the primary member based at least on a characteristic of the member porosity. The braze material may also infiltrate the thermal transfer structure(s), which may have the same or different porosity from the primary member. The thermal transfer structure(s) exhibit enhanced heat rejection, reduce weight of the component, and may improve component vibratory response.

Abstract: A metal coupon for repairing a component includes an additively manufactured (AM) metal member having a conduit in an interior of the AM metal member, and a first porous region around the conduit. The conduit is hollow. The porous metal coupon with conduit allows a braze material to be directed based on characteristics of the first porous region. A second porous region may be provided inside the conduit to increase heat rejection of the conduit.

Abstract: A metal coupon for repairing a component includes an additively manufactured (AM) metal member having a sealed cavity in an interior of the AM metal member, and a porous region around the sealed cavity. A metal coupon system may include at least two AM metal parts with each AM metal part including at least a section of a sealed cavity therein and a porous region around the at least section of the sealed cavity. The AM metal parts combine to form the metal coupon, i.e., AM metal member, with the sealed cavity in an interior thereof and the porous region around the sealed cavity. In any event, the sealed cavity is hollow. The metal coupon with the sealed cavity provides reduced mass and allows braze material to be directed based on characteristics of the porous region of the metal coupon.

Abstract: A metal coupon for repairing a component includes an additively manufactured (AM) metal member having at least two porous regions and a braze material infiltration barrier positioned between the at least two porous regions. The braze material infiltration barrier has a lower porosity than the at least two porous regions. A component using the metal coupon may also include a braze material coupling the metal coupon in a coupon opening in the body. The braze material infiltrates at least one of the two porous regions, and the braze material infiltration barrier separates the braze material in the at least one of the two porous regions from at least one other of the at least two porous regions. Different braze materials may be used in each porous region.

Abstract: An additive manufactured (AM) metal coupon for a turbomachine component is provided. The component includes an airfoil body having a pressure side, a suction side, a trailing edge, and a coupon opening. The AM metal coupon has an AM metal member with at least one slanted coupon side wall at an angle of less than 90° with an exterior surface of the AM metal member. The AM metal member also has a first porous region having a first porosity and a second porous region having a second porosity different than the first porosity. A braze material couples the AM metal coupon in the coupon opening in the airfoil body and infiltrates into at least one of the first porous region based at least on a characteristic of the first porosity and the second porous region based at least on a characteristic of the second porosity.

Abstract: A component includes a body and an additively manufactured (AM) metal coupon that includes at least one first porous region having a first porosity and may include any number of second porous regions having a second porosity different than the first porosity. A braze material couples the metal coupon in a coupon opening in the body. The braze material infiltrates into at least one of the first porous region based at least on a characteristic of the first porosity or any second porous region based at least on a characteristic of the second porosity. The different porosities can be customized to provide the first porous region and the second porous region with the braze material therein with different physical characteristic(s).

Abstract: A method of coupling a metal coupon to a component may include additively manufacturing the metal coupon having a first porous region having a first porosity and a second porous region having a second porosity different than the first porosity. The metal coupon is positioned in a coupon opening in a body of the component. The metal coupon may be infiltrated with a braze material to couple the metal coupon in the coupon opening in the body. One or more braze materials infiltrate into at least one of the first porous region based at least on a characteristic of the first porosity and the second porous region based at least on a characteristic of the second porosity. The cured braze material includes different sections having different physical characteristics based on the different porosities and/or different braze materials(s).

Abstract: A tip rail cooling insert for attaching into a tip rail pocket in a tip rail of a turbine blade is disclosed. The insert includes a first inner layer defining at least one first insert cooling channel therein, the first inner layer including a pair of spaced legs defining a first coolant collection plenum with at least the tip rail pocket for directing coolant from at least one internal cooling cavity in the turbine blade to the at least one first insert cooling channel. Each of the pair of spaced legs has an angled outer end configured to accommodate rounded inner corners of the tip rail pocket. A first outer layer is on a first side of the first inner layer, and a second outer layer is on a second side of the first inner layer.

Abstract: A turbine blade tip cooling system includes a turbine blade having a tip cavity, a tip rail surrounding at least a portion of the tip cavity and at least one internal cooling cavity. The tip rail has an inner rail surface, an outer rail surface, an end surface and at least one tip rail pocket open at the end surface and fluidly connected to the at least one internal cooling cavity that carries a coolant. A tip rail cooling insert attaches to the at least one tip rail pocket, and has insert cooling channel(s) and a coolant collection plenum for directing coolant from the at least one internal cooling cavity to the insert cooling channel(s).

Abstract: A tip rail cooling insert for attaching into a tip rail pocket in a tip rail of a turbine blade is disclosed. The insert includes a first inner layer defining at least one first insert cooling channel therein, the first inner layer including a pair of spaced legs defining a first coolant collection plenum with at least the tip rail pocket for directing coolant from at least one internal cooling cavity in the turbine blade to the at least one first insert cooling channel. Each of the pair of spaced legs has an angled outer end configured to accommodate rounded inner corners of the tip rail pocket. A first outer layer is on a first side of the first inner layer, and a second outer layer is on a second side of the first inner layer.

Abstract: A turbine blade tip cooling system includes a turbine blade having a tip cavity, a tip rail surrounding at least a portion of the tip cavity and at least one internal cooling cavity. The tip rail has an inner rail surface, an outer rail surface, an end surface and at least one tip rail pocket open at the end surface and fluidly connected to the at least one internal cooling cavity that carries a coolant. A tip rail cooling insert attaches to the at least one tip rail pocket, and has insert cooling channel(s) and a coolant collection plenum for directing coolant from the at least one internal cooling cavity to the insert cooling channel(s).

Abstract: A hybrid diffusion-brazing process and hybrid diffusion-brazed article are disclosed. The hybrid diffusion-brazing process includes providing a component having a temperature-tolerant region and a temperature-sensitive region, brazing a braze material to the temperature-tolerant region during a localized brazing cycle, then heating the component in a furnace during a diffusion cycle. The brazing and the heating diffusion-braze the braze material to the component, and the localized brazing cycle is performed independent of the diffusion cycle in the hybrid diffusion-brazing process. The hybrid diffusion-brazed article includes a component, and a braze material diffusion-brazed to the component with a filler material. The filler material has a melting temperature that is above a tolerance temperature of the component.

Abstract: Blockages of turbomachine cooling circuit cooling holes resulting from coating processes can be removed by introducing a cleaning agent into the cooling circuit. The cooling circuit can be connected to a cleaning agent supply under pressure, adding force on the blockage to chemical action by the cleaning agent. The cleaning agent is chemically reactive with the coating material and substantially chemically non-reactive with the underlying material of the cooling circuit and other parts of the turbomachine. A neutralization agent can also be introduced to reduce toxicity and/or action of the cleaning agent. A turbomachine cooling hole cleaning method includes introducing a cleaning agent into a cooling circuit of a turbomachine part, pressurizing the cleaning agent in the cooling circuit until a first defined condition is met, and introducing a neutralization agent to the turbomachine part while the cleaning agent is applied to the cooling circuit.

Abstract: Blockages of turbomachine cooling circuit cooling holes resulting from coating processes can be removed by introducing a cleaning agent into the cooling circuit. The cooling circuit can be connected to a cleaning agent supply under pressure, adding force on the blockage to chemical action by the cleaning agent. The cleaning agent is chemically reactive with the coating material and substantially chemically non-reactive with the underlying material of the cooling circuit and other parts of the turbomachine. A neutralization agent can also be introduced to reduce toxicity and/or action of the cleaning agent. A turbomachine cooling hole cleaning method includes introducing a cleaning agent into a cooling circuit of a turbomachine part, pressurizing the cleaning agent in the cooling circuit until a first defined condition is met, and introducing a neutralization agent to the turbomachine part while the cleaning agent is applied to the cooling circuit.

Abstract: A modification process and modified article are disclosed. The modification process includes locating an area in an article, removing the area by machining to form a machined region, inserting a modification material into the machined region, securing the modification material to the article, machining the modification material flush with a geometry of the article, and applying a coating over at least a portion of the article. Another modification process includes locating an area under a suction side leading edge tip shroud fillet of an airfoil, removing the area by machining to form a hole, inserting a modification material having improved material properties as compared to an original base material into the hole, securing the modification material in place, machining the modification material and the airfoil to form a new fillet contour, and applying a coating over at least a portion of the airfoil. Also disclosed is the modified article.