Methods and apparatuses for attachment of porous coatings to implants and products thereof

A method of forming an implant comprising a biocompatible alloy implant body and one or more bonded porous metallic ingrowth structures bonded to one more bone-interfacing alloy surfaces of the biocompatible alloy implant body, the method comprising:

• forming an assembly including one more bone-interfacing alloy surfaces of the biocompatible alloy implant body;
• placing a collapsible metallic layer onto the one more bone-interfacing alloy surfaces of the biocompatible alloy implant body, wherein the collapsible metallic layer is configured to collapse/crumble under compression thereby creating an interface;
• and
• placing one or more preformed porous metallic ingrowth structures into contact with the collapsible metallic layer so that the collapsible metallic layer is between the one or more preformed porous metallic ingrowth structures and the one more bone-interfacing alloy surfaces of the biocompatible alloy implant body;
• heating the assembly to a temperature and for a time sufficient to cause solid-state diffusion bonding of the one or more preformed porous metallic ingrowth structures to the one more bone-interfacing alloy surfaces of the biocompatible alloy implant body, thereby forming the one or more bonded porous metallic ingrowth structures;
• and
• applying a force to compress the one or more preformed porous metallic ingrowth structures onto the one more bone-interfacing alloy surfaces of the biocompatible alloy implant body during the heating of the assembly,
• wherein the biocompatible alloy implant body further comprises one or more articulating implant body surfaces, and wherein the heating of the assembly creates a diffusion hardened layer of increased thickness on the one or more articulating surfaces.