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 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: 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 for redirection of coolant flow is provided. The method includes an identifying step that identifies a hot spot on an exterior surface of a body of a component of a turbine system. A first parameter of the component indicates that a temperature of the exterior surface in the hot spot exceeds a threshold value. Another identifying step identifies a cool spot on the exterior surface. A second parameter of the component indicates that the temperature of the exterior surface in the cool spot is below the threshold value. A reconfiguring step reconfigures a plurality of cooling passages of the component to direct a portion of a coolant from the cool spot to the hot spot.

Abstract: A method for redirection of coolant flow is provided. The method includes an identifying step that identifies a hot spot on an exterior surface of a body of a component of a turbine system. A first parameter of the component indicates that a temperature of the exterior surface in the hot spot exceeds a threshold value. Another identifying step identifies a cool spot on the exterior surface. A second parameter of the component indicates that the temperature of the exterior surface in the cool spot is below the threshold value. A reconfiguring step reconfigures a plurality of cooling passages of the component to direct a portion of a coolant from the cool spot to the hot spot.

Abstract: A robotic treatment system includes a robotic arm comprising a tool mount, and a plurality of tools, each of the plurality of tools removably connectable to the tool mount. The system further includes a distribution assembly, which includes a distribution source, a distribution feed cable, a distribution return cable, and a plurality of distribution valves. Each of the plurality of distribution valves regulates a distribution flow through the distribution feed cable to one of the plurality of tools or the distribution return cable from one of the plurality of tools. The system further includes a supply assembly, which includes a supply controller, a plurality of substrate feeders, and a plurality of supply feed cables. The system further includes a main controller, the main controller in operable communication with the robotic arm, the supply controller, and each of the plurality of distribution valves.

Abstract: A robotic treatment system includes a robotic arm comprising a tool mount, and a plurality of tools, each of the plurality of tools removably connectable to the tool mount. The system further includes a distribution assembly, which includes a distribution source, a distribution feed cable, a distribution return cable, and a plurality of distribution valves. Each of the plurality of distribution valves regulates a distribution flow through the distribution feed cable to one of the plurality of tools or the distribution return cable from one of the plurality of tools. The system further includes a supply assembly, which includes a supply controller, a plurality of substrate feeders, and a plurality of supply feed cables. The system further includes a main controller, the main controller in operable communication with the robotic arm, the supply controller, and each of the plurality of distribution valves.

Abstract: A method of forming a component having an internal passage defined therein is provided. The method includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed at least partially by an additive manufacturing process, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core is positioned to define the internal passage within the component.

Abstract: A mold assembly for use in forming a component having an internal passage defined therein includes a mold defining a mold cavity therein, and a jacketed core positioned with respect to the mold. The jacketed core includes a hollow structure, and an inner core disposed within the hollow structure and positioned to define the internal passage within the component when a component material in a molten state is introduced into the mold cavity and cooled to form the component. The jacketed core also includes a first coating layer disposed between the hollow structure and the inner core.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from at least a first material and a first catalyst, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from at least a first material and a second material, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

Abstract: Embodiments of the present invention provide a cooling and sealing air system for a gas turbine power plant operating in a configuration that includes a stoichiometric exhaust gas recirculation configuration. A user may have flexibility in determining where the cooling and sealing flow derives. This may include an enhanced oil recovery system, a concentrated carbon system, etc.

Abstract: A method of forming a component having an internal passage defined therein includes forming a precursor core having a shape corresponding to a shape of the internal passage, and forming a hollow structure around the precursor core. The method also includes removing the precursor core from within the hollow structure, and disposing an inner core within the hollow structure to form a jacketed core. The method further includes positioning the jacketed core with respect to a mold, and introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the hollow structure from a portion of the jacketed core within the cavity. Additionally, the method includes cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

Abstract: A mold assembly for use in forming a component having an internal passage defined therein is provided. The component is formed from a component material. The mold assembly includes a mold that defines a mold cavity therein. The mold assembly also includes a lattice structure selectively positioned at least partially within the mold cavity. The lattice structure is formed from a first material that has a selectively altered composition in at least one region of the lattice structure. A channel is defined through the lattice structure, and a core is positioned in the channel such that at least a portion of the core extends within the mold cavity and defines the internal passage when the component is formed in the mold assembly.