Novel Highly Porous Metal Technology in Artificial

Hip and Knee Replacement: Processing

Methodologies and Clinical Applications

JOHN MUTH, MATTHEW POGGIE, GENE

KULESHA, and R. MICHAEL MENEGHINI
Journal of the Minerals, Metals and Materials Society, Vol. 65, No. 2,
2013
6/16/15

Paper Objective:
This article provides an overview of
several processes used to fabricate metal
implant porous surfaces.

6/16/15

Egypt-Japan University of Science and

Technology (E-Just)

Contents:
1- Introduction.
2- Methods.
2.1- Thermal spray technology.
2.2- Wire Arc Deposition.
2.3- Plasma Spray.
2.4- Porous Beads.
2.5- Diffusion-bonding.
2.6- Zimmer Trabecular Metal.
2.7- Stryker porous architecture.

3- Performance Criteria.
4- Critique.
6/16/15

Egypt-Japan University of Science and

Technology (E-Just)

1-Introduction
Fixation of hip and knee replacement
implants to bone is critical to the success
of the procedure.
A variety of roughened surfaces and threedimensional porous surfaces have been
used to enhance biological fixation on
orthopedic implants.

6/16/15

Egypt-Japan University of Science and

Technology (E-Just)

2.2- Wire Arc Deposition

The technology employs a specially designed
gun through which two CPTi sacrificial wires are
fed.
At the front of the gun, an electrical arc is struck
between the tips of the two wires melting them.
The resulting localized melt is then atomized by
a high-pressure stream of argon gas, causing
the fine, molten titanium particles to be sprayed
onto the implant.
6/16/15

Egypt-Japan University of Science and

Technology (E-Just)

2.3- Plasma Spray

The process uses fine powder particles (10 200
m) as a feedstock and a plasma gun with a
cathode and water-cooled anode, which are not
sacrificial.
The powder particles are continuously fed via a
specialized hopper into a plasma flame (12,000
oC).
After melting in the flame, the molten particles
are propelled by the guns high-pressure inert
gas onto the implant surface.
6/16/15

Egypt-Japan University of Science and

Technology (E-Just)

2.4- Porous Beads

The starting feedstock material is spherical
beads that are 500700 m in diameter made
of a cobalt chromium molybdenum alloy.
The fabrication steps begin with applying a
binder to the beads and the implant surface.
Following this gluing step, the bead-coated
implants are subjected to a high-temperature
sinter cycle in a vacuum furnace under inert
conditions.
6/16/15

Egypt-Japan University of Science and

Technology (E-Just)

2.5- Diffusion-bonding
In one method, CPTi wire is cut into
predetermined lengths, compacted, and
diffusion bonded to a Ti alloy implant
surface.
Because of the random nature of the wiremesh structure, the pore size generally
varies but overall porosity in the range of
50% can be achieved.
6/16/15

Egypt-Japan University of Science and

Technology (E-Just)

2.5- Diffusion-bonding
Another process employs CPTi powder
that is sintered to a Ti alloy surface under
high pressure and temperature.
An interconnected network of pores is
created that can yield coatings with an
overall porosity near 55%.

6/16/15

Egypt-Japan University of Science and

Technology (E-Just)

2.6- Zimmer Trabecular Metal

Zimmer (USA) provides a highly porous
surface for implant fixation that uses
Tantalum as the biomaterial.
This porous material is produced through
the chemical vapor deposition of tantalum
onto a carbon core that was formed from
the thermal degradation of a polymer
foam.
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Egypt-Japan University of Science and

Technology (E-Just)

10

2.6- Zimmer Trabecular Metal

Porous tantalum provides the important
biomechanical properties of increased
material elasticity and a high coefficient of
friction (0.880.98).
Furthermore, the modulus of elasticity of
porous-tantalum is in between cortical and
cancellous bone, significantly less than
titanium and cobalt chromium materials,
which decrease stress shielding.
6/16/15

Egypt-Japan University of Science and

Technology (E-Just)

11

2.7- Stryker porous architecture

Stryker (USA) has produced an open,
porous 3-D surface using CPTi powder.
The process begins by machining a
scaffold from a commercially available,
polyurethane foam to a desired form.
The interconnecting pore structure of this
sacrificial material provides the architecture
for the resulting metallic structure.
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Egypt-Japan University of Science and

Technology (E-Just)

12

2.7- Stryker porous architecture

The machined foam is coated with a thin
layer of CPTi.
The CPTi coated polyurethane structure is
placed on a solid Ti alloy surface and the
assembly is placed in a vacuum furnace.
A sinter cycle is run whereby the
polyurethane is volatilized and evacuated
leaving the lightly sintered CPTi skin in the
image of the polyurethane foam.
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Egypt-Japan University of Science and

Technology (E-Just)

13

3- Performance Criteria
Testing is conducted to characterize the
static tensile, static shear, and shear
fatigue strength of the porous surface.
A U.S. Food and Drug Administration
guidance
document
recommends
minimum performance criteria of 20 MPa
tensile strength.

6/16/15

Egypt-Japan University of Science and

Technology (E-Just)

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