Metal coupon with porous regions and slanted side wall(s) for turbomachine component

A turbomachine component, comprising:

• an airfoil body having a pressure side, a suction side, and a trailing edge;
• an additively manufactured (AM) metal coupon having a pair of oppositely slanted coupon side walls each with a convex curvature, a first porous region having a first porosity, a second porous region having a second porosity different than the first porosity, a solid region between the first porous region and the second porous region, and a cooling passage, wherein the cooling passage extends through the solid region, and wherein the cooling passage extends through an external surface of the metal coupon;
• and
• a braze material coupling the AM metal coupon in a coupon opening in the airfoil body, the braze material infiltrated into at least one of the first porous region based at least on a characteristic of the first porosity and infiltrated into the second porous region based at least on a characteristic of the second porosity,
• wherein the coupon opening includes oppositely slanted coupon opening side walls mating with the coupon side walls each with a concave curvature corresponding to the convex curvature of a respective one of the pair of oppositely slanted coupon side walls.

A method for coupling a metal coupon in a turbomachine component having an airfoil body having a pressure side, a suction side and a trailing edge, the method comprising:

• additively manufacturing the metal coupon having oppositely slanted walls each with a convex curvature wherein each of the oppositely slanted walls forms a respective angle with an exterior surface of the metal coupon, a first porous region having a first porosity, a second porous region having a second porosity different than the first porosity, a solid region between the first porous region and the second porous region, and a cooling passage wherein the cooling passage is formed through the solid region;
• positioning the metal coupon in a coupon opening in the airfoil body of the component, wherein the coupon opening includes mating oppositely slanted concave side walls to the coupon side walls, and wherein the cooling passage extends through an external surface of metal coupon;
• and
• infiltrating the metal coupon with a braze material to couple the metal coupon in the coupon opening in the airfoil body, wherein the infiltrating includes infiltrating the braze material 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.