Metal coupon with porous stress-relief section and component with same
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.
1 . A metal coupon, comprising:
an additively manufactured (AM) metal member including a first section having a first porosity and a stress-relief section, wherein the stress-relief section includes a porous region having a second porosity, wherein the second porosity is between 2% to 50% open space volume to total volume of the porous region of the stress-relief section, wherein the first porosity is less than the second porosity, wherein the stress-relief section has less cross-sectional area than the first section, wherein the stress-relief section is at least partially embedded within the AM metal member; and
wherein the stress-relief section has at least one of thermal conductivity, tensile strength, ductility, or fatigue strength less than at least one respective thermal conductivity, tensile strength, ductility, or fatigue strength of the first section.
2 . The metal coupon of claim 1 , wherein the stress-relief section is fully embedded within the AM metal member.
3 . The metal coupon of claim 1 , wherein the stress-relief section includes a first portion embedded within the first section and a second portion that extends to an exterior surface of the AM metal member.
4 . The metal coupon of claim 1 , wherein the stress-relief section is within a single layer of the AM metal member.
5 . The metal coupon of claim 4 , wherein the single layer of the AM metal member extends only partially across the AM metal member.
6 . The metal coupon of claim 1 , wherein the stress-relief section extends at least partially across at least two layers of the AM metal member.
7 . The metal coupon of claim 1 , wherein the porous region is a first porous region, the stress-relief section includes a first sub-section having the first porous region and a second sub-section having a second porous region, the first porous region having a respective porosity between 2% to 50% open space volume to total volume of the first porous region and the second porous region having a respective porosity between 2% to 50% open space volume to total volume of the second porous region, and wherein the porosity of the first porous region is less than the porosity of the second porous region; and
wherein the first sub-section and the second sub-section have a difference between at least one of respective thermal conductivity, respective tensile strength, respective ductility, or respective fatigue strength.
8 . A metal coupon, comprising:
an additively manufactured (AM) metal member including a first section that has a first porosity and a stress-relief section that includes a porous region that has a second porosity, wherein the second porosity is between 2% to 50% open space volume to total volume of the porous region of the stress-relief section, wherein the first porosity is different than the second porosity; and
wherein the AM metal member further comprises a braze material that alters the at least one of thermal conductivity, tensile strength, ductility, or fatigue strength responsive to the braze material being infiltrated into the stress-relief section.
9 . The metal coupon of claim 8 , further comprising a crack in the first section and wherein the crack stops at the stress-relief section responsive to the braze material infiltrating the crack.
10 . The metal coupon of claim 8 , wherein the stress-relief section includes a first portion embedded within the first section and a second portion that extends to an exterior surface of the AM metal member.
11 . The metal coupon of claim 10 , further comprising a crack in the first section, wherein the crack stops at the stress-relief section responsive to the braze material infiltrating the crack.
12 . A component, comprising:
a body;
an additively manufactured (AM) metal coupon including a first section that has a first porosity and a stress-relief section that includes a porous region that has a second porosity, wherein the second porosity is between 2% to 50% open space volume to total volume of the porous region of the stress-relief section, wherein the second porosity is higher than the first porosity, wherein the stress-relief section has less cross-sectional area than the first section, wherein the stress-relief section has at least one of thermal conductivity, tensile strength, ductility, or fatigue strength less than at least one respective thermal conductivity, tensile strength, ductility, or fatigue strength of the first section; and
a braze material coupling the AM metal coupon to a coupon opening in the body.
13 . The component of claim 12 , wherein the braze material infiltrates into the stress-relief section and the at least one of thermal conductivity, tensile strength, ductility, or fatigue strength of the stress-relief section is altered responsive to infiltration by the braze material.
14 . The component of claim 13 , further comprising a crack in the first section, wherein the crack stops at the stress-relief section, wherein the braze material infiltrates the crack.
15 . The component of claim 12 , wherein the stress-relief section is fully embedded within the AM metal coupon.
16 . The component of claim 12 , wherein the stress-relief section includes a first sub-section embedded within the first section and a second sub-section that extends to an exterior surface of the AM metal coupon.
17 . The component of claim 16 , further comprising a braze material infiltrated into the stress-relief section and the at least one of thermal conductivity, tensile strength, ductility, or fatigue strength of the stress-relief section is altered responsive to infiltration by the braze material.
18 . The component of claim 17 , further comprising a crack in the first section, wherein the crack stops at the stress-relief section, wherein the braze material infiltrates the crack.
19 . The component of claim 12 , wherein the stress-relief section is within a single layer of the AM metal coupon.
20 . The component of claim 19 , wherein the single layer of the AM metal coupon extends only partially across the AM metal coupon.
21 . The component of claim 12 , wherein the stress-relief section extends at least partially across at least two layers of the AM metal coupon.