Method for fabricating a biocompatible material having a high carbide phase and such material

Patent metadata

Field	Value
Publication number	US-9776246-B2
Application number	US-201414553343-A
Country	US
Kind code	B2
Filing date	Nov 25, 2014
Priority date	Mar 26, 2007
Publication date	Oct 3, 2017
Grant date	Oct 3, 2017

Abstract

A method of fabricating a material having a high concentration of a carbide constituent. The method may comprise adding a carbide source to a biocompatible material in which a weight of the carbide source is at least approximately 10% of the total weight, heating the carbide source and the biocompatible material to a predetermined temperature to melt the biocompatible material and allow the carbide source to go into solution to form a molten homogeneous solution, and impinging the molten homogeneous solution with a high pressure fluid to form spray atomized powder having carbide particles. The size of a particle of carbide in the atomized powder may be approximately 900 nanometers or less. The biocompatible material may be cobalt chrome, the carbide source may be graphite, and the fluid may be a gas or a liquid.

First claim

The invention claimed is:

1. Method of fabricating a material having a high concentration of a carbide constituent and utilizing said material to coat at least one surface of a component, said method comprising:
adding a carbide source to cobalt chrome or an alloy thereof, in which a weight of the carbide source is at least approximately 50% of a total weight of the carbide source and the cobalt chrome or the alloy thereof and in which the carbide source includes graphite;
heating the carbide source and the cobalt chrome or the alloy thereof to a predetermined temperature to melt the cobalt chrome or the alloy thereof and allow the carbide source to go into solution so as to form a molten homogeneous solution; and
impinging the molten homogeneous solution with a high pressure fluid so as to form spray atomized powder having carbide particles, in which a size of a carbide particle in the atomized powder is approximately 900 nanometers or less, and
coating the at least one surface of the component with the spray atomized powder having carbide particles.

2. The method according to claim 1 , in which the size of said carbide particle in the atomized powder is within a range of approximately 10-200 nanometers.

3. The method according to claim 1 , in which the predetermined temperature is approximately 200-300 degrees Centigrade over a melting temperature of the cobalt chrome or the alloy thereof.

4. The method according to claim 1 , in which the fluid is a gas.

5. The method according to claim 4 , in which the gas is argon or nitrogen.

6. The method according to claim 1 , in which the fluid is a liquid.

7. The method according to claim 6 , in which the liquid is water.

8. The method according to claim 1 , in which the weight of the carbide source is at least approximately 75% of the total weight of the carbide source and the cobalt chrome or the alloy thereof.

9. The method according to claim 1 , in which the weight of the carbide source is at least approximately 99% of the total weight of the carbide source and the cobalt chrome or the alloy thereof.

Assignees

• Howmedica Osteonics Corp

Inventors

• Lawrynowicz Daniel E
• Wang Aiguo
• Zhang Zongtao
• Zeng Haitong

Classifications

• B22F1/06

  Metallic powder characterised by the shape of the particles (nanosized particles B22F1/054) · CPC title

• C22C32/0052

  only carbides · CPC title

• B22D23/00

  Casting processes not provided for in groups B22D1/00 - B22D21/00 (making metallic powder by casting B22F9/08; alumino-thermic welding B23K23/00; remelting metals C22B9/16) · CPC title

• B22F2009/0848

  Melting process before atomisation · CPC title

• B22F1/0007

  Operations & Transport · mapped topic