Sintering of biocompatible P/M Co-Cr-Mo alloy (F-75) for fabrication of porosity-graded composite structures

Manufacturing of complex-shaped bimetals utilizing two-color powder injection molding (2C-PIM) and three-dimensional printing (3DP) processes, which basically involve sintering of a powder/binder mixture, has been attracted a great interest. This article addresses sintering of biocompatible Co-Cr-Mo alloy for manufacturing stepwise porosity-graded composite structures. Such composite structures provide strength at the core and a porous layer for the tissue growth. To evaluate the process, two grades of gas atomized Co-Cr-Mo powder with an average particle size of 19 and 63 mu m were used. Isothermal and non-isothermal sintering behavior of the loose powders under hydrogen and argon atmospheres, which is a simulated condition of 2C-PIM and 3DP processes after de-binding, was studied. Microstructural characteristics of the sintered specimens were evaluated. It was found that an intermediate sintering temperature of 1280 degrees C in argon can be used for manufacturing of the porosity-graded composite layers, i.e., a relatively dense core (5% porosity) with a porous layer (33% porosity) can be produced. A hip-joint with a core/shell structure was produced as a case study. (c) 2007 Elsevier B.V. All rights reserved.