Braze repair using metal coupon with porous region

A component, comprising:

• a body having a coupon opening defined therein;
• and
• an additively manufactured (AM) metal coupon including a dense region that has a porosity of less than 1% open space volume to total volume of the dense region such that a braze material cannot infiltrate the dense region, a porous region adjacent the dense region and that has a porosity between 2% to 50% open space volume to total volume of the porous region, and a coupon outer surface, wherein 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, wherein
• at least part of the porous region is between a corresponding part of the dense region and the coupon outer surface that engages the coupon opening responsive to the AM metal coupon being inserted into the coupon opening.

A method of repairing a component having a defect and a component surface, the method comprising:

• removing at least part of the defect at the component surface by forming a coupon opening in the component;
• additively manufacturing a metal coupon, the additively manufactured (AM) metal coupon produced thereby including:
• forming a dense region with a porosity of less than 1% open space volume to total volume of the dense region such that a braze material cannot infiltrate the dense region;
• forming with a porous region a porosity between 2% to 50% open space volume to total volume of the porous region;
• and
• forming a coupon outer surface as part of at least the porous region, wherein 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;
• and
• positioning the additively manufactured (AM) metal coupon in the coupon opening such that a coupon outer surface of the AM metal coupon engages the coupon opening, the AM metal coupon.