# US 2014/0151342 A1 · Resistance welding a porous metal layer to a metal substrate > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0151342 A1 - Document ID: US20140151342A1 - Status: Published application - Kind: A1 - Application number: 14/175,036 - Filed: 2014-02-07 - Published: 2014-06-05 - Earliest claimed: 2010-11-18 - Assignees: Zimmer, Inc. - Applicants: Zimmer, Inc. - Inventors: Joseph R. Vargas; Steven Seelman; Clarence M. Panchison - Web page: https://patentgrep.com/patent/US20140151342A1 ## CPC - B23K 11/18: of non-ferrous metals (B23K11/20 takes precedence) - A61F 2/30907: {Nets or sleeves applied to surface of prostheses or in cement} - A61F 2/3094: {Designing or manufacturing processes} - A61F 2/36: Femoral heads {; Femoral endoprostheses} - B23K 11/163: {Welding of coated materials} - A61F 2002/30451: {soldered or brazed or welded} - A61F 2002/3092: {having an open-celled or open-pored structure} - A61F 2310/00023: Titanium or titanium-based alloys, e.g. Ti-Ni alloys - A61F 2310/00407: Coating made of titanium or of Ti-based alloys - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C) ## Abstract An apparatus and method are provided for manufacturing an orthopedic prosthesis by resistance welding a porous metal layer of the orthopedic prosthesis onto an underlying metal substrate of the orthopedic prosthesis. The resistance welding process involves directing an electrical current through the porous layer and the substrate, which dissipates as heat to cause softening and/or melting of the materials, especially along the interface between the porous layer and the substrate. The softened and/or melted materials undergo metallurgical bonding at points of contact between the porous layer and the substrate to fixedly secure the porous layer onto the substrate. ## Claims ### Claim 1 (canceled) ### Claim 2 A method of manufacturing an orthopedic prosthesis comprising the steps of: providing a metal substrate; providing a porous component, the porous component including a porous structure having an outer surface coated with a metal coating; positioning the porous component against the metal substrate, wherein said metal coating provides an interfacing surface contacting the metal substrate; and directing an electrical current to the interfacing surface to bond the porous component to the metal substrate. ### Claim 3 (depends on 2) The method of claim 2, wherein said porous component comprises titanium. ### Claim 4 (depends on 2) The method of claim 2, wherein said porous component comprises tantalum. ### Claim 5 (depends on 2) The method of claim 2, wherein said metal coating is chemical vapor deposited onto said outer surface and infiltrates said porous structure. ### Claim 6 (depends on 2) The method of claim 2, wherein the porous component is provided in the form of a layer. ### Claim 7 (depends on 6) The method of claim 6, wherein said layer is provided having a thickness, and wherein said thickness is maintained during said positioning and directing steps. ### Claim 8 A method of manufacturing an orthopedic prosthesis comprising the steps of: providing a metal substrate; providing a porous metal component; positioning the porous metal component against the metal substrate at an interface, wherein said positioning generates a net contact area between the porous metal component and the metal substrate at said interface; applying a weld pressure of at least 100 psi holding the porous metal component against the metal substrate, wherein said net contact area is maintained during said applying step; and directing an electrical current to the interface between the porous metal component and the metal substrate to bond the porous metal component to the metal substrate. ### Claim 9 (depends on 8) The method of claim 8, wherein said porous metal component is in the form of a layer. ### Claim 10 (depends on 8) The method of claim 8, wherein said positioning avoids compressing said porous metal component. ### Claim 11 (depends on 8) The method of claim 8, wherein said porous metal component comprises tantalum or titanium. ### Claim 12 (depends on 8) The method of claim 8, wherein said porous metal component includes a porous structure having an outer surface coated with a metal coating providing an interfacing surface contacting the metal substrate over said net contact area. ### Claim 13 (depends on 12) The method of claim 12, wherein said metal coating is chemical vapor deposited onto said outer surface. ### Claim 14 A method of manufacturing an orthopedic prosthesis comprising the steps of: providing a metal substrate; providing a porous metal component; positioning the porous metal component against the metal substrate at an interface without compressing the porous metal component, wherein said positioning brings an outer surface of the porous metal component into contact with the metal substrate at said interface to generate a net contact area between the porous metal component and the metal substrate at said interface; and directing an electrical current to the interface to bond the porous metal component to the metal substrate, wherein said net contact area is maintained during said directing step. ### Claim 15 (depends on 14) The method of claim 14, wherein said porous metal component is a porous layer having a thickness. ### Claim 16 (depends on 15) The method of claim 15, wherein said porous layer includes open pores remaining open over the thickness of the porous layer as said electrical current is directed to said interface. ### Claim 17 (depends on 14) The method of claim 14, wherein a weld pressure of between 100 psi and 3,000 psi is applied to hold the porous metal component against the metal substrate. ### Claim 18 (depends on 14) The method of claim 14, wherein said porous metal component comprises titanium or tantalum. ### Claim 19 (depends on 14) The method of claim 14, wherein said outer surface is coated with a metal coating contacting the metal substrate. ### Claim 20 (depends on 19) The method of claim 19, wherein said metal coating is chemical vapor deposited onto said outer surface. ### Claim 21 A method of manufacturing an orthopedic prosthesis comprising the steps of: providing a metal substrate; providing a porous component that includes a porous structure having an outer surface coated with a metal coating forming an outer coated surface; positioning the porous component against the metal substrate so that said outer coated surface contacts the metal substrate at an interface, wherein said positioning avoids compressing the porous component yet includes applying a weld pressure of at least 100 psi holding the porous component against the metal substrate; and directing an electrical current to the interface to bond the porous component to the metal substrate. ### Claim 22 (depends on 21) The method of claim 21, wherein said metal coating is chemical vapor deposited onto said outer surface.