Pressure forming of metal and ceramic powders
View Patent ↗A method of pressure forming a brown part from metal and/or ceramic particle feedstocks includes: introducing into a mold cavity or extruder a first feedstock and one or more additional feedstocks or a green or brown state insert made from a feedstock, wherein the different feedstocks correspond to the different portions of the part; pressurizing the mold cavity or extruder to produce a preform having a plurality of portions corresponding to the first and one or more additional feedstocks, and debinding the preform. Micro voids and interstitial paths from the interior of the preform part to the exterior allow the escape of decomposing or subliming backbone component substantially without creating macro voids due to internal pressure. The large brown preform may then be sintered and subsequently thermomechanically processed to produce a net wrought microstructure and properties that are substantially free the interstitial spaces.
1. A brown metal, a brown ceramic, or a brown metal and ceramic preform, the preform comprising:
a) at least one insert, the insert comprising an insert metal powder, an insert ceramic powder, or an insert metal and ceramic powder mixture; and
b) a first composition surrounding the at least one insert, the first composition comprising:
i) a first composition metal powder, a first composition ceramic powder, or a combination of the first composition metal and ceramic powders; and
ii) a binder comprising a carrier component,
c) wherein at least the first composition has a microstructure that includes micro voids and interstitial paths, the interstitial paths residing between and connecting to adjacent micro voids, and
d) wherein the micro voids of the first composition have a micro void size that is about 1-10 times a particle size of the first composition metal powder, the first composition ceramic powder, or the combination of the first composition metal and ceramic powders.
2. The preform of claim 1 configured for use as or in a medical device.
3. The preform of claim 1 wherein, after sintering and then forging, at least the first composition has a density that is at least 98% of the first composition's theoretical density prior to being sintered.
4. The preform of claim 1 wherein the insert is relatively less dense than the surrounding first composition.
5. The preform of claim 1 wherein at least the first composition comprises a biocompatible first composition metal selected from the group consisting of a cobalt alloy, titanium, a titanium alloy, and a stainless steel alloy.
6. The preform of claim 1 having a length greater than 4 inches along any dimension.
7. The preform of claim 1 being of a size sufficient to contain a 12 mm diameter sphere.
8. The preform of claim 1 having a thickness greater than 12 mm.
9. The preform of claim 1 wherein the at least one insert is a green state insert.
10. The preform of claim 1 wherein the at least one insert is a brown state insert.
11. The preform of claim 1 wherein the at least one insert is both a green state and a brown state insert.
12. The preform of claim 1 wherein the first composition comprises at least one first composition metal powder having particles from about 2 microns to about 150 microns in size.
13. The preform of claim 12 wherein the at least one first composition metal powder has particles from about 25 microns to about 150 microns in size.
14. The preform of claim 1 wherein the first composition metal powder is selected from the group consisting of: a cobalt alloy, a titanium or titanium alloy and a stainless steel.
15. The preform of claim 1 wherein the first composition comprises a blend of at least one first composition metal powder and at least one first composition ceramic powder.
16. The preform of claim 15 wherein the at least one first composition ceramic powder is from about 1% to about 20% by weight of the blend.
17. The preform of claim 15 wherein the at least one first composition ceramic powder is from about 80% to about 99% by weight of the blend.
18. The preform of claim 1 wherein neither the insert nor the first composition is a wrought portion.
19. The preform of claim 1 wherein the binder is selected from the group consisting of acetal, polyethylene, polypropylene, polyethylene glycol, polyalkylene glycol, paraffin wax, oleic acid, polysaccharide (agar), naphthalene or paradichlorobenzene or combinations thereof, and combinations thereof.
20. The preform of claim 1 having a complex geometry.
21. The preform of claim 1 configured for use:
a) in a hip replacement assembly, the preform being selected from the group consisting of a acetabular shell, a femoral head, and a femoral stem;
b) in a knee replacement assembly, the preform being selected from the group consisting of a femoral component and a tibial tray;
c) in a shoulder replacement assembly, the preform being selected from the group consisting of a humeral stem, a glenoid sphere, and a glenoid fixation device;
d) as a lumbar fixation device;
e) as an orthopedic screw;
f) as a vertebral disc replacement device; and
g) in a spinal fixation assembly.
22. The preform of claim 1 wherein the insert has a second composition that is different than the first composition.
23. A brown metal, a brown ceramic, or a brown metal and ceramic preform, the preform comprising:
a) a plurality of inserts, each insert of an insert metal powder, an insert ceramic powder, or an insert metal and ceramic powder mixture, wherein at least two of the plurality of inserts are of different insert compositions of the insert metal powder, the insert ceramic powder, or the insert metal and ceramic powder mixture; and
b) a first composition surrounding the plurality of inserts, the first composition comprising:
i) a composition metal powder, a composition ceramic powder, or a combination of composition metal and composition ceramic powders; and
ii) a binder comprising a carrier component,
c) wherein at least the first composition has a microstructure that includes micro voids and interstitial paths characteristic of the carrier component having been volatilized from the binder; and
d) wherein the micro voids of the first composition have a micro void size that is about 1-10 times a particle size of the first composition metal powder, the first composition ceramic powder, or the combination of the first composition metal and ceramic powders.
24. The preform of claim 23 configured for use as or in a medical device.
25. The preform of claim 23 wherein the insert comprise an insert metal powder, an insert ceramic powder, or an insert metal and ceramic powder mixture.
26. The preform of claim 23 wherein, after sintering and then forging, at least the first composition has a density that is at least 98% of the first composition's theoretical density prior to being sintered.
27. The preform of claim 23 wherein the insert is relatively less dense than the surrounding first composition.
28. The preform of claim 23 wherein at least the first composition comprises a biocompatible first composition metal selected from the group consisting of a cobalt alloy, titanium, a titanium alloy, and a stainless steel alloy.
29. The preform of claim 23 having a length greater than 4 inches along any dimension.
30. The preform of claim 23 being of a size sufficient to contain a 12 mm diameter sphere.
31. The preform of claim 23 having a thickness greater than 12 mm.
32. The preform of claim 23 wherein the at least one insert is a green state insert.
33. The preform of claim 23 wherein the at least one insert is a brown state insert.
34. The preform of claim 23 wherein the at least one insert is both a green state and a brown state insert.
35. The preform of claim 23 wherein the first composition comprises at least one first composition metal powder having particles from about 2 microns to about 150 microns in size.
36. The preform of claim 35 wherein the at least one first composition metal powder has particles from about 25 microns to about 150 microns in size.
37. The preform of claim 23 wherein the first composition metal powder is selected from the group consisting of: a cobalt alloy, a titanium or titanium alloy and a stainless steel.
38. The preform of claim 23 wherein the first composition comprises a blend of at least one first composition metal powder and at least one first composition ceramic powder.
39. The preform of claim 38 wherein the at least one first composition ceramic powder is from about 1% to about 20% by weight of the blend.
40. The preform of claim 38 wherein the at least one first composition ceramic powder is from about 80% to about 99% by weight of the blend.
41. The preform of claim 23 wherein neither the insert nor the first composition is a wrought portion.
42. The preform of claim 23 wherein the binder is selected from the group consisting of acetal, polyethylene, polypropylene, polyethylene glycol, polyalkylene glycol, paraffin wax, oleic acid, polysaccharide (agar), naphthalene or paradichlorobenzene or combinations thereof, and combinations thereof.
43. The preform of claim 23 having a complex geometry.
44. The preform of claim 23 configured for use:
a) in a hip replacement assembly, the preform being selected from the group consisting of a acetabular shell, a femoral head, and a femoral stem;
b) in a knee replacement assembly, the preform being selected from the group consisting of a femoral component and a tibial tray;
c) in a shoulder replacement assembly, the preform being selected from the group consisting of a humeral stem, a glenoid sphere, and a glenoid fixation device;
d) as a lumbar fixation device;
e) as an orthopedic screw;
f) as a vertebral disc replacement device; and
g) in a spinal fixation assembly.
45. The preform of claim 23 wherein the insert has a second composition that is different than the first composition.
46. A brown metal, a brown ceramic, or a brown metal and ceramic preform, the preform comprising:
a) a plurality of inserts, each insert of the same insert metal powder, insert ceramic powder, or insert metal and ceramic powder mixture, wherein at least two of the plurality of inserts are of different particles sizes of the insert metal powder, the insert ceramic powder, or the insert metal and ceramic powders; and
b) a first composition surrounding the plurality of inserts, the first composition comprising:
i) a composition metal powder, a composition ceramic powder, or a combination of composition metal and ceramic powders; and
ii) a binder comprising a carrier component,
c) wherein at least the first composition has a microstructure that includes micro voids and interstitial paths characteristic of the carrier component having been volatilized from the binder; and
d) wherein the micro voids of the first composition have a micro void size that is about 1-10 times a particle size of the first composition metal powder, the first composition ceramic powder, or the first composition metal and ceramic powders.
47. The preform of claim 46 configured for use as or in a medical device.
48. The preform of claim 46 wherein the insert comprise an insert metal powder, an insert ceramic powder, or an insert metal and ceramic powder mixture.
49. The preform of claim 46 wherein, after sintering and then forging, at least the first composition has a density that is at least 98% of the first composition's theoretical density prior to being sintered.
50. The preform of claim 46 wherein the insert is relatively less dense than the surrounding first composition.
51. The preform of claim 46 wherein at least the first composition comprises a biocompatible first composition metal selected from the group consisting of a cobalt alloy, titanium, a titanium alloy, and a stainless steel alloy.
52. The preform of claim 46 having a length greater than 4 inches along any dimension.
53. The preform of claim 46 being of a size sufficient to contain a 12 mm diameter sphere.
54. The preform of claim 46 having a thickness greater than 12 mm.
55. The preform of claim 46 wherein the at least one insert is a green state insert.
56. The preform of claim 46 wherein the at least one insert is a brown state insert.
57. The preform of claim 46 wherein the at least one insert is both a green state and a brown state insert.
58. The preform of claim 46 wherein the first composition comprises at least one first composition metal powder having particles from about 2 microns to about 150 microns in size.
59. The preform of claim 58 wherein the at least one first composition metal powder has particles from about 25 microns to about 150 microns in size.
60. The preform of claim 46 wherein the first composition metal powder is selected from the group consisting of: a cobalt alloy, a titanium or titanium alloy and a stainless steel.
61. The preform of claim 46 wherein the first composition comprises a blend of at least one first composition metal powder and at least one first composition ceramic powder.
62. The preform of claim 61 wherein the at least one first composition ceramic powder is from about 1% to about 20% by weight of the blend.
63. The preform of claim 62 wherein the at least one first composition ceramic powder is from about 80% to about 99% by weight of the blend.
64. The preform of claim 46 wherein neither the insert nor the first composition is a wrought portion.
65. The preform of claim 46 wherein the binder is selected from the group consisting of acetal, polyethylene, polypropylene, polyethylene glycol, polyalkylene glycol, paraffin wax, oleic acid, polysaccharide (agar), naphthalene or paradichlorobenzene or combinations thereof, and combinations thereof.
66. The preform of claim 46 having a complex geometry.
67. The preform of claim 46 configured for use:
a) in a hip replacement assembly, the preform being selected from the group consisting of a acetabular shell, a femoral head, and a femoral stem;
b) in a knee replacement assembly, the preform being selected from the group consisting of a femoral component and a tibial tray;
c) in a shoulder replacement assembly, the preform being selected from the group consisting of a humeral stem, a glenoid sphere, and a glenoid fixation device;
d) as a lumbar fixation device;
e) as an orthopedic screw;
f) as a vertebral disc replacement device; and
g) in a spinal fixation assembly.
68. The preform of claim 46 wherein the insert has a second composition that is different than the first composition.
69. A brown metal, a brown ceramic, or a brown metal and ceramic preform, the preform comprising:
a) at least one insert; and
b) a first composition surrounding the at least one insert, the first composition comprising:
i) a first composition metal powder, a first composition ceramic powder, or a combination of the first composition metal and ceramic powders; and
ii) a binder comprising a carrier component,
c) wherein at least the first composition has a microstructure that includes micro voids and interstitial paths, the interstitial paths residing between and connecting to adjacent micro voids, and
d) wherein the micro voids of the first composition have a micro void size that is about 1-10 times a particle size of the first composition metal powder, the first composition ceramic powder, or the combination of the first composition metal and ceramic powders.
70. The preform of claim 69 wherein the at least one first composition ceramic powder is from about 1% to about 20% by weight of the blend.
71. The preform of claim 69 wherein the at least one first composition ceramic powder is from about 80% to about 99% by weight of the blend.
72. The preform of claim 69 wherein the at least one insert is a green state insert.
73. The preform of claim 69 wherein the at least one insert is a brown state insert.
74. The preform of claim 69 wherein the at least one insert is both a green state and a brown state insert.