Metal alloy having rhenium effect

A medical device that is partially or fully formed of a metal alloy;

• said metal alloy includes rhenium in an amount of at least 15 awt. % of said metal alloy;
• said metal alloy including one or more alloying metals selected from the group consisting of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, chromium, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lithium, magnesium, manganese, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, zinc, and zirconium;
• a combined weight percent of rhenium and alloying metals is at least 70 wt. % of said metal alloy;
• said metal alloy has a) an increase of at least 10% in ductility as compared to said metal alloy that is absent rhenium, and/or b) an increase of at least 10% in tensile strength.

A method for forming a metal alloy that includes at least 15 awt. % rhenium comprising:

• a. providing metal powder;
• said metal powder having i) an average particle size of 2-62 microns, ii) an average density of greater than 5 g/cm3, and/or iii) Hall flow (s/50 g) of less than 30 seconds;
• said metal powder at least partially having a metal composition of at least 15 awt. % rhenium and one or more alloying metals selected from the group consisting of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, chromium, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lithium, magnesium, manganese, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, zinc, and zirconium;
• a combined weight percent of rhenium and alloying metals is at least 70 wt. % of said metal alloy;
• and
• b. using 3D printing technology or direct metal printing technology to form said metal powder into a) a metal rod, b) a metal film, c) a metal sheet, d) a metal tube, e) a component of a medical device, or f) a medical device.

A metal alloy that includes rhenium;

• said metal alloy comprises:
• I) at least 15 awt. % rhenium, at least 50 wt. % iron, and one or more alloy I alloying metals selected from a) 10-28 wt. % chromium, b) 0-35 wt. % nickel, b) 0-4 wt. % molybdenum, d) 0-2 wt. % manganese, e) 0-0.75 wt. % silicon, f) 0-5 wt. % titanium, g) 0-10 wt. % niobium, h) 0-5 wt. % copper, i) 0-4 wt. % aluminum, j) 0-10 wt. % tantalum, k) 0-1 wt. % selenium, 1) 0-2 wt. % vanadium, and m) 0-2 wt. % tungsten;
• and wherein a combined weight percent of said rhenium, iron and said alloy I alloying metals is greater than 95 wt. %;
• or
• II) at least 15 awt. % rhenium, 30-68 wt. % cobalt, 15-32 wt. % chromium, and one or more alloy II alloying metals selected from a) 1-36% wt. % nickel, b) 2-18 wt. % molybdenum, c) 0-18 wt. % iron, d) 0-1 wt. % titanium, e) 0-0.15 wt. % manganese, f) 0-0.15 wt. % silver, g) 0-16 wt. % tungsten, h) 0-2 wt. % silicon, i) 0-2 wt. % aluminum, and j) 0-1 wt. % iron;
• and wherein a combined weight percent of said rhenium, cobalt, chromium and said alloy II alloying metals is greater than 95 wt. %;
• or
• III) at least 15 awt. % rhenium, 5.5-6.75 wt. % aluminum, 3.5-4.5 wt. % vanadium, 85-93 wt. % titanium, and one or more alloy III alloying metals selected from a) 0-0.4 wt. % iron, b) 0-0.05 wt. % yttrium;
• and wherein a combined weight percent of said rhenium, aluminum, vanadium, titanium and said alloy III alloying metals is greater than 95 wt. %;
• or
• IV) at least 15 awt. % rhenium, 40-85 wt. % niobium, and one or more alloy IV alloying metals selected from a) 0.01-20 wt. % molybdenum, b) 0.01-35 wt. % tantalum, c) 0.01-12 wt. % hafnium, d) 0.01-5 wt. % zirconium, e) 0.01-3 wt. % titanium, f) 0.01-15 wt. % tungsten, and g) 0.01-1 wt. % yttrium;
• and wherein a combined weight percent of said rhenium, niobium, and said alloy IV alloying metals is greater than 95 wt. %;
• or
• VI) at least 15 awt. % rhenium, 30-58 wt. % titanium, and 30-58 wt. % nickel;
• and wherein a combined weight percent of said rhenium, titanium, and nickel is greater than 95 wt. %;
• or
• VII) at least 15 awt. % rhenium, and one or more of a) 1-85 awt. % chromium, b) 0.1-10 awt. % titanium, c) 0.1-10 awt. % molybdenum, and d) 0.1-10 awt. % zirconium;
• and wherein a combined weight percent of said rhenium, chromium, titanium, molybdenum, and zirconium is greater than 95 wt. %;
• or
• VII) at least 15 awt. % rhenium and one or more Type VII alloying metals selected from the group consisting of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, chromium, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lithium, magnesium, manganese, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, zinc, and zirconium;
• and wherein a combined weight percent of said rhenium, said alloy VII alloying metals is greater than 95 wt. %.