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Title:
COMBINATION OF PROCESSES FOR MAKING WROUGHT COMPONENTS
Document Type and Number:
WIPO Patent Application WO/2001/014602
Kind Code:
A2
Abstract:
The present invention combines pre-wrought processes with conventional forging processes to produce orthopaedic components at reduced cost and lead-time, but comparable to conventional forging in ductility and strength. In this invention, the wrought barstock used conventionally for forging feedstock is replaced with a preform, blank, bar or other pre-wrought material exhibiting the required ductile strength and refined grain structure to be forgeable. A critical aspect of this invention is that the fine grain structure of the pre-wrought material provides improved ductile strength and sufficient forgeability to the material. This bar or preform may then be forged to produce grain size refinement and increase in material integrity. Three categories of pre-wrought processes according to the invention include forming the material using metal molds; processes that achieve the necessary ductility and refined grain structure for wrought processing through rapid heat removal through the component or a quenching atmosphere or gas; and processes that achieve the necessary ductility and refined grain structure through consolidation of powder or semi-solid material under conditions which restrict coarsening of the grain structure.

Inventors:
LONG MARK (US)
HUNTER GORDON (US)
Application Number:
PCT/US2000/023267
Publication Date:
March 01, 2001
Filing Date:
August 24, 2000
Export Citation:
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Assignee:
SMITH & NEPHEW INC (US)
LONG MARK (US)
HUNTER GORDON (US)
International Classes:
A61L27/04; A61L27/06; A61L31/02; B22D15/00; B22F3/17; B22F3/22; C22C1/00; C22F1/00; C22F1/10; C22F1/18; (IPC1-7): C21D7/00
Domestic Patent References:
WO1991013181A11991-09-05
WO1998033610A11998-08-06
Foreign References:
EP0665299A11995-08-02
EP0414620A11991-02-27
GB1472939A1977-05-11
US4775426A1988-10-04
US5729883A1998-03-24
Other References:
DATABASE WPI Section Ch, Week 198428 Derwent Publications Ltd., London, GB; Class M22, AN 1984-173383 XP002159468 -& JP 59 094555 A (SHOWA KEIKINZOKU KK), 31 May 1984 (1984-05-31)
G.N.COLVIN: "TITANIUM '95 :SCIENCE AND TECHNOLOGY, PAGES 691-701, "PERMANENT MOULD CASTING OF TITANIUM AEROSPACE AND AUTOMOTIVE HARDWARE" " 1995 , INSTITUTE OF MATERIALS , LONDON, GB XP000957923 cited in the application
Attorney, Agent or Firm:
Pratt, John S. (GA, US)
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Claims:
What is claimed is:
1. A process for producing a component, comprising: a. casting a blank using a metal mold which imparts sufficient conductive heat transfer from the blank to achieve rapid cooling of the blank in order to produce a blank which features a refined grain structure sufficient to prevent cracking or non uniform flow during forging ; and b. subsequently forging the blank to produce said component.
2. A process according to claim 1 in which the blank is cast from a cobalt chrome alloy.
3. A process according to claim 2 in which the cobalt chrome alloy is a Co28Cr 6Mo alloy.
4. A process according to claim 1 in which the blank is cast from a titanium alloy.
5. A process according to claim 1 in which the blank is cast from a zirconium alloy.
6. A process according to claim 1 in which the blank is cast from a stainless steel alloy.
7. A process according to claim 1 in which the casting process is a gravity metal mold process.
8. A process according to claim 1 in which the casting process is a vacuum die casting process.
9. A process according to claim 2 in which the blank after casting features a grain size smaller than 300 pm.
10. A process according to claim 2 in which the blank after casting features a grain size smaller than 150 m.
11. A process according to claim 2 in which the blank after casting features an ultimate tensile strength of at least 665 MPa.
12. A process according to claim 3 in which the component after forging complies with ASTM F79996.
13. A process for producing an orthopaedic component, comprising: a. casting a blank from a cobalt chrome alloy using a metal mold which imparts sufficient conductive heat transfer from the blank to achieve cooling of the blank in order to produce grain size smaller than 300 m and ultimate tensile strength of at least 665 MPa; and b. subsequently forging the blank to produce said component, the component complying with ASTM F79996.
14. A process according to claim13 in which the casting process is a gravity metal mold process.
15. A process according to claim 13 in which the casting process is a vacuum die casting process.
16. A process according to claim 13 in which the grain size of the blank is smaller than 150 jj. m.
17. A process for producing a component, comprising: a. forming a blank by incrementally applying material to portions of the blank already formed, thus building the blank in a manner which imparts conductive heat transfer from the applied material to portions of the blank already built to achieve rapid cooling of the applied material in order to produce a blank which features a refined grain structure sufficient to prevent cracking or nonuniform flow during forging; and b. subsequently forging the blank to produce said component.
18. A process according to claim 17 in which the material is also applied in a manner which imparts conductive heat transfer from the applied material to a gas surrounding the applied material to achieve cooling of the applied material.
19. A process according to claim 17 in which the blank is formed of a cobalt chrome alloy.
20. A process according to claim 19 in which the cobalt chrome alloy is a Co28Cr 6Mo alloy.
21. A process according to claim 17 in which the blank is formed of a titanium alloy.
22. A process according to claim 17 in which the blank is formed of a zirconium alloy.
23. A process according to claim 17 in which the blank is formed of a stainless steel alloy.
24. A process according to claim 17 in which the forming process is a spray forming process.
25. A process according to claim 17 in which the forming process is an electron beam forming process.
26. A process according to claim 17 in which the forming process is a laser beam forming process.
27. A process according to claim 19 in which the blank after forming features a grain size smaller than 300 pm.
28. A process according to claim 19 in which the blank after forming features a grain size smaller than 150, um.
29. A process according to claim 19 in which the blank after forming features an ultimate tensile strength of at least 665 MPa.
30. A process according to claim 20 in which the component after forging complies with ASTM F79996.
31. A process for producing an orthopaedic component, comprising: a. forming a blank from a cobalt chrome alloy by incrementally applying material to portions of the blank already formed, thus building the blank in a manner which imparts conductive heat transfer from the applied material to portions of the blank already built and to a gas in the presence of the applied material to achieve rapid cooling of the applied material, the resulting grain size of the material in the blank smaller than 300 m and the ultimate tensile strength of the material at least 665 MPa; and b. subsequently forging the blank to produce said component, the component complying with ASTM F79996.
32. A process according to claim 31 in which the forming process is a spray forming process.
33. A process according to claim 31 in which the forming process is an electron beam forming process.
34. A process according to claim 31 in which the forming process is a laser beam forming processs.
35. A process according to claim 31 in which the grain size of the blank is smaller than 150 pm.
36. A process for producing a component, comprising: a. forming a blank by consolidating a powderized material under at least temperature and pressure conditions sufficient to restrict coarsening of grain structure of the material in order to produce a blank which features a refined grain structure sufficient to prevent cracking or nonuniform flow during forging; and b. subsequently forging the blank to produce said component.
37. A process according to claim 36 in which the blank is formed of a cobalt chrome alloy.
38. A process according to claim 37 in which the cobalt chrome alloy is a Co28Cr 6Mo alloy.
39. A process according to claim 36 in which the blank is formed of a titanium alloy.
40. A process according to claim 36 in which the blank is formed of a zirconium alloy.
41. A process according to claim 36 in which the blank is formed of a stainless steel alloy.
42. A process according to claim 36 in which the forming process is a metal injection molding process.
43. A process according to claim 37 in which the blank after forming features a grain size smaller than 300 pm.
44. A process according to claim 37 in which the blank after forming features a grain size smaller than 150 m.
45. A process according to claim 37 in which the blank after forming features an ultimate tensile strength of at least 665 MPa.
46. A process according to claim 38 in which the component after forging complies with ASTM F79996.
47. A process for producing an orthopaedic component, comprising: a. forming a blank by metal injection molding a cobalt chrome alloy powder material to restrict coarsening of grain structure of the material, the resulting grain size of the material in the blank smaller than 300 um and the ultimate tensile strength of the material in the blank at least 665 MPa; and b. subsequently forging the blank to produce said component, the component complying with ASTM F79996.
48. A process according to claim 47 in which the grain size of the blank is smaller than 150 pm.
49. A process for producing a component, comprising: a. forming a blank by consolidating a semisolid material under at least temperature and pressure conditions sufficient to restrict coarsening of grain structure of the material in order to produce a blank which features a refined grain structure sufficient to prevent cracking or nonuniform flow during forging; and b. subsequently forging the blank to produce said component.
50. A process according to claim 49 in which the blank is formed of a cobalt chrome alloy.
51. A process according to claim 50 in which the cobalt chrome alloy is a Co28Cr 6Mo alloy.
52. A process according to claim 49 in which the blank is formed of a titanium alloy.
53. A process according to claim 49 in which the blank is formed of a zirconium alloy.
54. A process according to claim 49 in which the blank is formed of a stainless steel alloy.
55. A process according to claim 49 in which the forming process is a semi solid forming process.
56. A process according to claim 50 in which the blank after forming features a grain size smaller than 300 pm.
57. A process according to claim 50 in which the blank after forming features a grain size smaller than 150 um.
58. A process according to claim 50 in which the blank after forming features an ultimate tensile strength of at least 665 MPa.
59. A process according to claim 51 in which the component after forging complies with ASTM F79996.
60. A process for producing an orthopaedic component, comprising: a. forming a blank by semisolid forming a cobalt chrome alloy material to restrict coarsening of grain structure of the material, the resulting grain size of the material in the blank smaller than 300 jum and the ultimate tensile strength of the material in the blank at least 665 MPa; and b. subsequently forging the blank to produce said component, the component complying with ASTM F79996.
61. A process according to claim 60 in which the grain size of the blank is smaller than 150 m.
62. A component formed according to the process recited in claim 1.
63. An orthopaedic component formed according to the process recited in claim 13.
64. A component formed according to the process recited in claim 17.
65. An orthopaedic component formed according to the process recited in claim 31.
66. A component formed according to the process recited in claim 36.
67. An orthopaedic component formed according to the process recited in claim 47.
68. A component formed according to the process recited in claim 49.
69. An orthopaedic component formed according to the process recited in claim 60.
Description:
INTERNATIONAL SEARCH REPORT Interr ial Application No PCT/US00/23267 C. (Continuation) DOCUMENTS CONSIDERED TO BE RELEVANT Category ° Citation of document, with indication, where appropriate, of the relevant passages Relevant to claim No. A EP 0 414 620 A (PECHINEY RECHERCHE) 17 27 February 1991 (1991-02-27) page 4, paragraph 2; claim 1 A GB 1 472 939 A (OSPREY METALS LTD) 17 11 May 1977 (1977-05-11) claim 1 A WO 98 33610 A (AMCAN CASTINGS LIMITED) 49 6 August 1998 (1998-08-06) claim 1 A US 4 775 426 A (MURLEY JOHN ET AL) 4 October 1988 (1988-10-04) cited in the application A US 5 729 883 A (OIYAMA MAKOTO ET AL) 24 March 1998 (1998-03-24) cited in the application A G. N. COLVIN :"TITANIUM'95: SCIENCE AND TECHNOLOGY, PAGES 691-701,"PERMANENT MOULD CASTING OF TITANIUM AEROSPACE AND AUTOMOTIVE HARDWARE"" 1995, INSTITUTE OF MATERIALS, LONDON, GB XP000957923 cited in the application 1 INTERNATIONALSEARCH REPORT Interr nal Applicaton No .. tformatton on patent family members PCT/US 00/23267 PCT/US 00/23267 Patent document Publication Patent cited in search report date member (s) date EP 0665299 A 02-08-1995 JP 7224344 A 22-08-1995 DE 69423335 D 13-04-2000 DE 69423335 T 30-11-2000 US 6143097 A 07-11-2000 JP 59094555 A 31-05-1984 NONE WO 9113181 A 05-09-1991 US 5078806 A 07-01-1992 EP 0516750 A 09-12-1992 JP 5504602 T 15-07-1993 EP 0414620 A 27-02-1991 FR 2651244 A 01-03-1991 CA 2023900 A 25-02-1991 DE 69006293 D 10-03-1994 DE 69006293 T 26-05-1994 JP 1822336 C 10-02-1994 JP 3097824 A 23-04-1991 JP 5034411 B 24-05-1993 NO 176483 B 02-01-1995 US 5073207 A 17-12-1991 GB 1472939 A 11-05-1977 DE 2537103 A 04-03-1976 FR 2282315 A 19-03-1976 JP 1075654 C 25-12-1981 JP 51046554 A 21-04-1976 JP 56012220 B 19-03-1981 SE 7509264 A 23-02-1976 SE 7509264 A 23-02-1976 WO 9833610 A 06-08-1998 CA 2196479 A 01-08-1998 CA 2227828 A 31-07-1998 AU 5850098 A 25-08-1998 EP 1011897 A 28-06-2000 US 4775426 A 04-10-1988 NONE US 5729883 A 24-03-1998 JP 7227639 A 29-08-1995