Patent ID: 12188112

DETAILED DESCRIPTION

Alloy

Processes in accordance with embodiments of the invention modify stainless steel alloys that comply with (i) the ASTM F2229 stainless steel composition, e.g., commercially available BioDur® 108 stainless steel, (ii) the ASTM F1586 stainless steel composition, e.g., commercially available BioDur® 734 stainless steel, or (iii) high nitrogen, high chromium stainless steel (“HNHC stainless steel”), e.g., as described in U.S. Pat. No. 6,168,755, also described under the filing code ASM SS-1231 in the “Alloy Digest—Data on World Wide Metals and Alloys” published by ASM International (American Society for Metals), e.g., commercially available as Micro-Melt® NCORR™ stainless steel. All three of these commercially available alloys are manufactured by Carpenter Technology Corporation.

In particular, ASTM F2229 stainless steel is an essentially nickel- and cobalt-free nitrogen-strengthened stainless steel with excellent biocompatibility and approved by the Federal Drug Administration for medical use. It is produced by the Electro-Slag Remelting (ESR) process to assure its microstructural integrity and cleanness and is used in applications such as implantable orthopedic devices, high-strength surgical instrumentation, and orthodontic devices. With no intentional additions of cobalt, it complies with the European Union Medical Device Regulation 2017/745 that requires devices containing more than 0.10 wt. % cobalt content to indicate the presence of cobalt as a potential carcinogenic, mutagenic, reproductive toxin substance. ASTM F2229 stainless steel also does not contain intentionally added nickel, a metal known to cause cutaneous inflammations and to lead to allergy reactions, teratogenicity and carcinogenicity in medical application (see Yang et al., Nickel-free austenitic stainless steels for medical applications,Sci. Technol. Adv. Mater.11 (2010) 014105). Despite its known advantages, the use of ASTM F2229 stainless steel is limited in view of its relative softness when manufactured by conventional methods, e.g., typically about 300 HV. BioDur® 108 stainless steel manufactured by Carpenter Technology and CHRONIFER® 108 nickel free stainless steel distributed by L. Klein SA (Switzerland) are examples of an alloy compatible with the ASTM F2229 stainless steel standard.

ASTM F1586 stainless steel is an essentially cobalt-free nitrogen-strengthened stainless steel approved by the Federal Drug Administration for medical use. It is also compatible with the European Union Medical Device Regulation 2017/745 and used in implantable orthopedic parts such as bone plates, bone screws, and hip and knee components. The ASTM F1586 stainless steel standard calls for 9.00 to 11.00 wt. % Ni. BioDur® 734 manufactured by Carpenter Technology is an example of an alloy compatible with the ASTM F1586 stainless steel standard.

HNHC stainless steel is an essentially cobalt-free nitrogen-strengthened stainless steel manufactured using a powder metallurgy process consisting in atomizing and consolidating powder to form a billet. It is also compatible with the European Union Medical Device Regulation 2017/745 and contains up to 8.00 wt. % Ni. Its composition renders it able to generate high levels of strength through cold working.

Stainless steels that may be processed in accordance with embodiments of the invention have compositions selected from the range indicated in the fifth column of Table 1 below. This range encompasses the ranges for the ASTM F2229 stainless steel composition, the ASTM F1586 stainless steel composition, and the HNHC stainless steel composition, which are also given in Table 1. The preferred limits for each element are discussed below. The balance of all three alloys is iron and impurities resulting from normal manufacture.

TABLE 1Composition of stainless steels in wt. %.ElementASTM F2229ASTM F1586HNHCRangeFeBal.Bal.Bal.Bal.Co<0.10<0.10<0.10<0.10Mn21.00-24.002.00-4.255.85-152.00-24.00Cr19.00-23.0019.5-22.027-3019.00-30Mo0.50-1.502.0-3.01.5-4.00.50-4.0N0.85-1.100.25-0.500.8-0.970.25-1.10Ni≤0.059.0-11.08-22≤22Nb00.25-0.800≤0.80C≤0.08≤0.08Impurity≤1only*P≤0.03<0.025≤0.02≤0.03S≤0.01≤0.01Impurity≤1only*Si≤0.75≤0.75Impurity≤1only*ONotNotImpurity≤1intentionallyintentionallyonly*addedaddedCu≤0.25≤0.25≤0.01≤0.25*silicon, oxygen, carbon, and sulfur such that (silicon + oxygen + carbon + sulfur) ≤ 1 wt. %

TABLE 2Exemplary compositions of HNHC stainless steels.Preferred #2Based on disclosure of(ASM SS-ElementU.S. Pat. No. 6,168,755Preferred #11231)FeBal.Bal.Bal.Co<0.10<0.10<0.10Mn6-155.85-6.156.00Cr27-3029.30-29.7029.50Mo1.5-4.01.85-2.152.00N0.8-0.970.80-0.900.85Ni8-2214.80-15.2015.00Nb000CImpurity only*≤0.030≤0.030PImpurity only≤0.020≤0.020SImpurity only*≤0.0040.004SiImpurity only*0.45-0.55≤0.50OImpurity only*NotNotintentionallyintentionallyaddedaddedCuImpurity only≤0.01≤0.01*silicon, oxygen, carbon, and sulfur such that (silicon + oxygen + carbon + sulfur) ≤ 1 wt. %

Cobalt is an element that is not intentionally added to any of the alloys in Tables 1 and 2. Residual cobalt resulting from normal manufacture is kept below 0.10 wt. % to be compatible with the European Union Medical Device Regulation 2017/745 and preferably below 0.010 wt. %.

The major function of manganese in the subject alloys is to increase solubility for nitrogen; the specific level of manganese (within the ranges listed in Tables 1 and 2) is selected to provide the desired nitrogen level. 21.00 wt. % to 24.00 wt. % of Ni is needed in ASTM F2229 stainless steel to allow up to 1.10 wt. % of N in solution. Only 2.00 wt. % to 4.25 wt. % of Ni is needed in ASTM F1586 stainless steel because the desired N level is 0.25 wt. % to 0.50 wt. % and the extra Ni contributes to the N solubility. The HNHC stainless steel requires up to 15 wt. % of Mn to allow 0.80 wt. % to 0.97 wt. % of N in solution.

Chromium increases both corrosion resistance and nitrogen solubility. However, increasing chromium also decreases austenitic stability. The level of chromium (within the ranges listed in Tables 1 and 2) is selected to provide the required corrosion resistance; the levels of other elements are then adjusted as necessary to maintain austenitic stability. The ASTM F2229 and ASTM F1586 stainless steels require similar levels of Cr (19.00 wt. % to 23.00 wt. %) to reach the desired corrosion resistance. The HNHC stainless steel requires 27 wt. % to 30 wt. % Cr for extra corrosion resistance and use in harsher environment.

Molybdenum significantly improves resistance to corrosion, particularly the types of localized corrosion of concern in implant applications. However, molybdenum also significantly decreases austenitic stability. Like chromium, the levels of molybdenum (within the ranges listed in Tables 1 and 2) are selected to provide the required corrosion resistance and are balanced by the other elements; the levels of other elements are then adjusted as necessary to maintain austenitic stability.

Nitrogen plays a key role in maintaining austenitic stability in the alloys listed in Tables 1 and 2, as well as significantly contributing to corrosion resistance and determining the strength level. A high level of nitrogen increases the strain hardening rate of a stainless steel during cold working, i.e., the strength gained during a cold working deformation step with a given level of cold working increases with the level of nitrogen. Excessive nitrogen levels can result in difficulties in melting, atomizing, consolidating, forging and other process steps. Nitrogen levels (within the ranges listed in Tables 1 and 2) are controlled by controlling the levels of the other elements that affect nitrogen solubility.

Silicon additions provide deoxidation during the melting and refining processes; the specific levels used depend upon the melting process employed. Since increasing silicon decreases both austenitic stability and nitrogen solubility, the silicon level is limited to 0.75 wt. % in ASTM F2229 and ASTM F1586 stainless steels, and no more than 1 wt. % (in total with silicon, oxygen, carbon and sulfur) in HNHC stainless steel described in, e.g., U.S. Pat. No. 6,168,755.

Phosphorus is not intentionally added but is present as an impurity in the raw materials commonly used for melting alloys such as those in Tables 1 and 2. Since excessive levels of phosphorus can decrease certain properties such as ductility, melting and refining procedures are used such that phosphorus level is less than 0.020 wt. % of 0.025 wt. % at most.

Like phosphorus, sulfur is not intentionally added, but is present as an impurity in the raw materials commonly used for melting alloys such as those in Tables 1 and 2. Since excessive levels of sulfur also can decrease certain properties such as ductility, melting and refining procedures are used such that the sulfur level is less than 0.010 wt. % in ASTM F2229 and ASTM F1586 stainless steels, and no more than 1 wt. % (in total with silicon, oxygen, carbon and sulfur) in HNHC stainless steel described in, e.g., U.S. Pat. No. 6,168,755.

Although copper is often added to stainless alloys to enhance resistance to certain types of corrosion, copper is not intentionally added to the alloys in Tables 1 and 2, which are typically intended for implant applications. The level of copper (which may be present as an impurity in raw materials) is restricted to less than 0.25 wt. % in ASTM F2229 and ASTM F1586 stainless steels and less than 0.01 wt. % in the HNHC stainless steel described in, e.g., U.S. Pat. No. 6,168,755.

Carbon in solid solution helps stabilize the austenite phase. Carbon also can combine with various elements to form carbide phases. Since formation of chromium carbides on grain boundaries can result in decreased corrosion resistance, austenitic alloys designed for high corrosion resistance often have low carbon levels. Carbon in the ASTM F2229 and ASTM F1586 stainless steel alloys is restricted to levels less than 0.08 wt. %, and no more than 1 wt. % (in total with silicon, oxygen, carbon and sulfur) in HNHC stainless steel described in, e.g., U.S. Pat. No. 6,168,755.

The processes described herein employ methods known to those of skill in the art to manufacture the alloys described above, and include multiple additional steps to form an article including a surface layer. The processes include melting of raw material, atomizing or casting the molten metal, conversion from ingot to billet during forging, and a final annealing heat treatment of the billet. This is followed by a cold working step, i.e., a deformation step performed at low temperature to shape the article and increase its bulk yield strength and ultimate tensile strength. Immediately after cold working, a case hardening step of the article is performed at low temperature to improve the properties of the surface of the article. Unlike conventional methods, the case hardening step is not preceded by an annealing step. Cold working strains the material and makes it stronger; in contrast, annealing relaxes the material and makes it softer.

Accordingly, annealing an article after cold working defeats the purpose of the cold working step, resulting in the alloy losing strength gained during cold working.

Billet Forming and Annealing

Ingots made from the ASTM F2229 stainless steel described above may be manufactured by arc melting or vacuum induction melting (VIM) followed by electro-slag remelting (ESR). After solidification, ingots of ASTM F2229 stainless steel are homogenized in a furnace to ensure a homogenous microstructure and converted to billets via hot working on a press or radial forging machine as per the Carpenter Technology BioDur® 108 technical datasheet, which is hereby incorporated by reference in its entirety, for all purposes (Carpenter Technology Corporation, CarTech® BioDur® 108 Alloy). After forging, billets of ASTM F2229 stainless steel may be annealed to a temperature ranging from 1900° F. (1038° C.) to 2100° F. (1149° C.) for a duration of one hour and then rapidly cooled to room temperature to prevent the formation of chromium nitrides between 1500° F. (816° C.) and 1800° F. (982° C.). Within the context of this disclosure, this annealing step is defined as a thermal process performed in air, protective atmosphere or vacuum to relax internal stresses and soften the material through recovery or recrystallization.

Ingots made from the ASTM F1586 stainless steel described above may be manufactured by arc melting or vacuum induction melting (VIM) followed by electro-slag remelting (ESR). After homogenization and forging, billets of ASTM F1586 stainless steel may be annealed to a temperature ranging from 1922° F. (1050° C.) to 2102° F. (1150° C.) and rapidly quenched to prevent the formation of chromium nitrides, as per the Carpenter Technology BioDur® 734 technical datasheet, which is hereby incorporated by reference in its entirety, for all purposes (Carpenter Technology Corporation, CarTech® BioDur® 734 Alloy)

The HNHC stainless steel may be manufactured using powder metallurgy (PM) technology to produce powder that is consolidated into fully dense ingots via hot isostatic pressing (HIP). After forging, the billets may be annealed at 2000° F. (1093° C.) for one hour and rapidly quenched to prevent the formation of chromium nitrides, as per the recommendations described under the filing code ASM SS-1231 in the “Alloy Digest—Data on World Wide Metals and Alloys”.

Cold Working

Cold working is defined as the forming step consisting of but not limited to a combination of cold rolling, cold drawing, shot peening, and/or pilgering performed at or below ⅔ of the solidus temperature. For most stainless steels, the solidus temperature (defined as the highest temperature below which the alloy is fully solid) is at least 2400° F. (1316° C.) and ⅔ of this temperature is about 1600° F. (871° C.). In the rest of the disclosure, a cold forming step is understood as a forming step performed between room temperature and 1600° F. (871° C.). Cold working performed in the 1000° F. (538° C.) to 1600° F. (871° C.) temperature range may sometimes be referred to as “warm working”. Accordingly, as used herein, “cold working” encompasses cold and warm working, i.e., a forming step performed between room temperature and 1600° F. (871° C.).

Warm working (cold working) performed in the 1000° F. (538° C.) to 1600° F. (871° C.) temperature range, may be a preferred processing step as a deformation performed in that temperature range is easier, i.e., requires less external strength applied to the article to reach the desired level of deformation. Deformation performed in the 1000° F. (538° C.) to 1600° F. (871° C.) temperature range introduces less defects (for example dislocations, point defects) in the article and creates less energy stored in the article. Articles with less stored energy available for recovery or recrystallization are more likely to maintain their required bulk strength during further process, such as a case hardening step.

Because of their specific chemistries and unlike most other steel alloys, there is no hardening mechanism that can be used to harden ASTM F2229 stainless steel, ASTM F1586 stainless steel or HNHC stainless steel at high temperature, and cold working is the only processing step that can harden them and make them compatible with load-bearing applications. Accordingly, the alloys are preferably cold worked (i.e., deformed at a low temperature below 1600° F./871° C.) to make them stronger.

ASTM F2229 stainless steel, ASTM F1586 stainless steel and HNHC stainless steel have different compositions and different work hardenability, i.e., they harden differently when subjected to the same cold forming step and require different levels of cold working to reach the same level of mechanical properties.

For example,FIG.1is adapted from MJ Walter, Stainless steel for medical implants: The high level of nitrogen in BioDur® 108 stainless steel provides enhanced mechanical and physical properties for medical implants,Adv. Mater. Process.164 (2006) 84-86, and also adapted from the Carpenter Technology BIODUR® 108 STAINLESS data sheet, which are hereby incorporated by reference in their entireties, for all purposes. Referring toFIG.1, ASTM F2229 stainless steel in the annealed condition (cold working=0%) offers 88 ksi yield strength (YS)/135 ksi ultimate tensile strength (UTS) at room temperature and 270 ksi YS/320 ksi UTS after 80% of cold working. A suitable cold working process of 15% is preferred for a part made of that alloy to reach the ASTM 799 standard mechanical properties (120 ksi YS/170 ksi UTS at room temperature), which is hereby incorporated by reference in its entirety, for all purposes. For other applications, a different level of cold working may be desired to target a specific combination of YS and UTS.

In another example,FIG.2is adapted from the Carpenter Technology BIODUR® 734 STAINLESS datasheet, which is hereby incorporated by reference in its entirety, for all purposes. Referring toFIG.2, ASTM F1586 stainless steel in the annealed condition offers 65 ksi YS/122 ksi UTS at room temperature and 128 ksi YS/170 ksi UTS after 35% of cold working. A suitable cold working process of at least 40% is preferred for a part made of that alloy to reach the ASTM 799 standard mechanical properties (120 ksi YS/170 ksi UTS at room temperature). Similarly, for other applications, a different level of cold working may be desired to target a specific combination of YS and UTS.

In a last example,FIG.3is adapted from the Carpenter Technology CarTech® Micro-Melt® NCORR™ Stainless Steel datasheet, which is hereby incorporated by reference in its entirety, for all purposes. The HNHC stainless steel in the annealed condition offers 100 ksi YS/153 ksi UTS at room temperature and 264 ksi YS/328 ksi UTS after 70% of cold working. A suitable cold working process of at least 15% is preferred for a part made of that alloy to reach the ASTM 799 standard mechanical properties (120 ksi YS/170 ksi UTS at room temperature). Similarly, for other applications, a different level of cold working may be desired to target a specific combination of YS and UTS.

Case Hardening

Case hardening is a surface modification process used to harden the surface layer of stainless steels. Accordingly, a case-hardening step may be used to increase the hardness of the surface of ASTM F2229 stainless steel, ASTM F1586 stainless steel, or HNHC stainless steel such as ASM SS-1231 stainless steel via diffusion of interstitial elements such as carbon, nitrogen, boron or a combination thereof in, for example, a gas, ion or plasma media or in vacuum. In the case of pack carburizing, pack nitriding or pack boriding, the case hardening step may be conducted in a material that is enriched in carbon, nitrogen, or boron. This step may include carburizing, nitriding, boriding, carbonitriding or a combination thereof at a case hardening temperature below 1000° C. to prevent the formation of deleterious second phases. This process results in the formation of a surface layer that is much harder than the bulk of the material and also has improved resistance to wear, corrosion, and fatigue damage.

Case hardening can be used to improve the surface properties of ASTM F2229 stainless steel, ASTM F1586 stainless steel or HNHC stainless steel and improve the corrosion, fatigue and wear resistance of these alloys, resulting in better performances in various applications, such as articulating orthopedic applications.

In particular, case hardening is a heat treatment process in a C-rich, N-rich, B-rich, or a combination thereof or other suitable environment used to alter the near surface chemistry of the alloy through a diffusion process to alter the properties. It allows interstitial elements to diffuse into the surface layer of the material. The case-hardening process can be boriding (diffusion of boron), carburizing (diffusion of carbon), nitriding (diffusion of nitrogen), carbonitriding (simultaneous diffusion of carbon and nitrogen) or a combination thereof. The case hardening process can be performed using gas, ion or plasma media or in vacuum. During the case hardening process, interstitial elements diffuse into the surface layer form a supersaturated solid solution at the surface of the material. The process is performed at a temperature sufficiently low to prevent the formation of precipitates and detrimental second phases such as borides, carbides, nitrides or carbonitrides. See X Y Li, N Habibi, T Bell, H Dong, “Microstructural characterisation of a plasma carburised low carbon Co—Cr alloy”,Surf Eng.23 (2007) 45-51. Case hardening temperatures range between 350° C. and 1000° C., e.g., 400° C. to 1000° C., and durations can be as long as 60 hours and as short as 1 hour. See, for example, S R Collins, P C Williams, S V Marx, A Heuer, F Ernst, H Kahn, “Low-Temperature Carburization of Austenitic Stainless Steels,” in:Heat Treat. Irons Steels, ASM International, 2014: pp. 451-460.

In some embodiments described herein, case hardening temperatures range between 400° C. and 1000° C., such as 500° C., 550° C., 750° C., or 960° C. In some embodiments, case hardening periods range from 1 hour to 16 hours, such as 1 hour, 4 hours, 5 hours or 16 hours. The temperature at which the alloy is case hardened increases the diffusivity of carbon, nitrogen and boron, i.e., the higher the case hardening temperature, the easier it is to introduce a larger amount of interstitial elements in the case layer and the thicker the caser layer. A case hardening step performed at a higher temperature is more efficient, i.e. faster, than the same case hardening step performed at a lower temperature but can lead in Cr- and N-rich stainless steels to the formation of carbide or nitride that are detrimental to the corrosion resistance of the alloy. The case hardening temperature and time must be balanced and adapted to the alloy composition to create the desired case layer thickness and avoid the formation of detrimental carbide and nitride.

A minimum case surface layer thickness of 10 μm is desired to allow parts to be machined, 100 μm is a more preferred thickness and 1,000 μm is an even more preferred thickness. A surface hardness of at least 400 HV is desired for applications that require wear resistance, preferably 800 HV, more preferably 900 HV and even more preferably 1200 HV. The combination of surface hardness and case layer thickness is determined by the final application, as some applications need a shallower but harder surface layer and others need a thicker but softer case surface layer.

The case hardening is performed at a single case hardening temperature to simplify the process and minimize the risk of forming deleterious phases during the heat up and cool down ramps. Samples may be subjected to other temperatures during the case hardening process, for example during the heating part of the cycle, from room temperature to the case hardening temperature, e.g., a carburizing temperature, and during the cooling part of the cycle, from the case hardening temperature to room temperature. The case hardening cycle may be interrupted (i.e., introduction of boron, carbon, and/or nitrogen temporarily stopped) to allow interstitial elements to diffuse into the surface layer of the material, while maintaining the material at the case hardening temperature. The case hardening cycle may also include a succession of short case hardening pulses at the case hardening temperature and diffusion periods to allow interstitial elements to diffuse into the surface layer of the material.

The case hardening process results in the formation of a surface layer that is much harder than the bulk of the material (see schematic example inFIG.4) and has improved resistance to wear, corrosion, and fatigue damage. In accordance with embodiments of the invention, cold-worked (including warm-worked) articles of ASTM F2229 stainless steel, ASTM F1586 stainless steel or HNHC stainless steel are subjected to case-hardening heat treatments.

A variety of case hardening heat treatment cycles are offered by various commercial vendors: Kolsterising® (proprietary to Bodycote), ExpaniteHigh-T, ExpaniteLow-T and SuperExpanite (proprietary to Expanite A/S) or Infracarb® (proprietary to ECM-USA). Similarly, commercial nitriding, carbonitriding or boriding case hardening heat treatment cycles are available from the same vendors.

An exemplary system for performing a case hardening step (carburizing step called pack carburizing) on stainless steels described herein is a high-temperature furnace, e.g., the RD7-KHE24 box furnace manufactured by Lucifer Furnaces Inc. A mixture of pelletized carbon and sodium carbonate anhydrous may be placed in a metallic container. A suitable composition may be 98% (in weight) of pelletized carbon and 2% (in weight) of sodium carbonate anhydrous. The metallic container may be a stainless steel rectangular box topped with a stainless steel lid and sealed with a high-temperature refractory cement. The metallic container with the mixture may then be placed into the furnace along with the article to be case hardened. The mixture and article are heated to the desired case hardening temperature for a sufficient period of time to obtain a surface layer on a top surface of the article with the desired concentration of interstitial elements, and are then rapidly cooled to room temperature via quenching in water, oil, air, or any other fluid.

After case hardening, interstitial elements in solution generate compressive stresses that make the surface layer much harder and more resistant to fatigue and wear than the bulk of the material. The higher concentration of interstitial elements in the surface layer makes it more resistant to corrosion damage.

Suitable levels of diffused interstitial elements in accordance with embodiments of the invention are as follows:ASTM F2229 stainless steelCarburizing: ASTM F2229 stainless steel contains at most 0.08 wt. % of carbon. After carburizing, the concentration of carbon in the surface layer is at least 0.10 wt. % and preferably at most 5.00 wt. %Nitriding: the typical nitrogen level in the ASTM F2229 stainless steel ranges between 0.85 wt. % and 1.10 wt. %. After nitriding, the nitrogen concentration in the surface layer ranges from at least 1.10 wt. % at a top surface thereof to a range of 0.85 wt. % to 1.10 wt. % N in the bulk material, with the nitrogen concentration in the surface layer being higher than in the bulk material.Boriding: the nominal composition of the ASTM F2229 stainless steel does not include boron. A boriding case-hardening heat treatment results in a surface layer that contains at least 0.05 wt. % B.Combinations thereof.ASTM F1586 stainless steelCarburizing: ASTM F1586 stainless steel contains at most 0.08 wt. % of carbon. After carburizing, the concentration of carbon in the surface layer is at least 0.10 wt. % and preferably at most 5.00 wt. %Nitriding: the typical nitrogen level in the ASTM F1586 stainless steel ranges between 0.25 wt. % and 0.50 wt. %. After nitriding, the nitrogen concentration in the surface layer ranges from at least 0.50 wt. % at a top surface thereof to a range of 0.25 wt. % and 0.50 wt. % N in the bulk material, with the nitrogen concentration in the surface layer being higher than in the bulk material.Boriding: the nominal composition of the ASTM F1586 stainless steel does not include boron. A boriding case-hardening heat treatment results in a surface layer that contains at least 0.05 wt. % B.Combinations thereof.HNHC stainless steelCarburizing: the HNHC stainless steel contains at most 0.03 wt. % of carbon. After carburizing, the concentration of carbon in the surface layer is at least 0.10 wt. % and preferably at most 5.00 wt. %Nitriding: the typical nitrogen level in the HNHC stainless steel between 0.80 wt. % and 0.90 wt. %. After nitriding, the nitrogen concentration in the surface layer ranges from at least 0.90 wt. % at a top surface thereof to a range of 0.80 wt. % to 0.80 wt. % N in the bulk material, with the nitrogen concentration in the surface layer being higher than in the bulk material.Boriding: the nominal composition of the HNHC stainless steel does not include boron. A boriding case-hardening heat treatment results in a surface layer that contains at least 0.05 wt. % B.Combinations thereof.
Applications

Examples of articles that may be made of the alloy described herein and processed in accordance with embodiments of the invention are as follows.

Embodiments of the invention include articulating orthopedic implants such as a hip prosthesis, knee, or shoulder joint prosthesis. Referring toFIG.5, a hip prosthesis500may include an acetabular socket510, an insert520, a femoral head530, a femoral trunnion540, and a femoral stem550. The insert520(e.g., polyethylene insert made of ultra-high-molecular-weight polyethylene or UHMWPE) may be disposed in contact with the acetabular socket510, between the acetabular socket and the femoral head530. The femoral trunnion540, i.e., a tapered portion of the hip prosthesis500, is disposed between the femoral head530and the femoral stem550. As illustrated, the femoral stem550may be implanted in a femur560of a patient. Accordingly, a hip joint prosthesis typically has at least three elements: femoral stem550including a stem portion and a neck (trunnion540) made of metal, a femoral head530made of metal or ceramic, and an acetabular socket510that can be made of metal, ceramic or polymer (e.g., polyethylene); these three elements may be fabricated from stainless steel in accordance with embodiments of the invention.

The metal processing methods described herein may be used to fabricate articulating orthopedic implants that include metal, such as: 1) metal on metal contact (MoM), 2) metal on polyethylene contact (MoP), 3) metal on ceramic contact (MoC) and (4) ceramic on metal contact (CoM). Accordingly, hip prosthesis elements that may fabricated in accordance with embodiments of the invention include a femoral stem, a femoral head, and an acetabular socket.

An element formed by processes described herein has the required mechanical properties to be used in the articulating part of the joint replacement. Examples of required mechanical properties include a bulk strength of 120 ksi YS and 170 ksi UTS at room temperature to make the article compatible with the ASTM 799 requirement and a hardness of at least 350 HV.

In particular, an articulating orthopedic device may include a first element consisting essentially of cold worked ASTM F2229 stainless steel, ASTM F1586 stainless steel or HNHC stainless steel and having a first articular surface; and a second element consisting essentially of cold worked ASTM F2229 stainless steel, ASTM F1586 stainless steel or HNHC stainless steel and having a second articular surface configured to articulate with the first articular surface. The first and second articular surfaces each include a surface layer consisting of hardened ASTM F2229 stainless steel, ASTM F1586 stainless steel or HNHC stainless steel with at least one of carbon, nitrogen, or boron diffused therein. In some embodiments, the first element may be an acetabular socket and the second element may be a femoral head. In other embodiments, the first element may be a femoral head and the second element may be a femoral stem.

Furthermore, flat discs made of ASTM F2229 stainless steel, ASTM F1586 stainless steel or HNHC stainless steel can be cold formed to produce acetabular shell blanks and further processed according to embodiments of the invention. Spinal rods can also be made from ASTM F2229 stainless steel, ASTM F1586 stainless steel or the HNHC stainless steel using the processes described herein.

In use, in a hip replacement, a damaged bone and cartilage may be removed and replaced with at least some prosthetic components. For example, a damaged femoral head may be removed and replaced with femoral head530attached to a femoral stem550that can be placed into the hollow center of the femur560by either cementing or press fitting the femoral stem550into the femur560. In another example, a damaged femoral head may be removed and replaced by placing the femoral head530on the upper part of the femoral stem. In many cases, the femoral head530includes a structure (e.g., ball structure) that connects to the femoral stem550via the femoral trunnion540. In another example, a damaged cartilage surface of a socket (acetabulum) may be removed and replaced with the acetabular socket510. In some cases, screws or cement are used to hold the socket in place. In another example, the insert520(e.g., a plastic, ceramic, or metal spacer) is inserted between the femoral head530and the acetabular socket510to allow for a smooth gliding surface.

Materials and methods described herein may be used to fabricate watch structural elements such as cases, rings, gears, bracelets, or sections thereof and pins to hold the bracelets.

Furthermore, materials and methods described herein may be used to fabricate non-magnetic parts for applications in the electrification and electronics markets that require high resistance to wear and corrosion such as retainer rings.

Moreover, materials and methods described herein may be used to fabricate instrumentation/non-magnetic housings for the oil & gas industry, as well as bearings, gears, gear teeth, and pump shafts.

Examples

The composition example in Table 1 describes articles made of ASTM F2229 stainless steel, ASTM F1586 stainless steel or HNHC stainless steel after a cold deformation and case hardening step. Further, exemplary compositions in weight percent are given in Table 3 below.

TABLE 3Composition in wt. % of the experimental stainless-steel alloys melted at Carpenter Technology.BioDur ® 108BioDur ® 734NCORR ™stainlessstainlessstainlessElementsteelsteelsteelFeBal.Bal.Bal.Co<0.01<0.10<0.01Mn22.963.235.98Cr21.1321.3229.44Mo0.682.421.98N1.050.280.804Ni0.0110.2315.24Nb0.010.38<0.01C0.0380.0470.027P0.0100.019<0.005S0.004<0.0010.002Si0.290.260.50ONotNotNotintentionallyintentionallyintentionallyaddedaddedaddedCu<0.010.23<0.01

The BioDur® 108-, BioDur® 734-, and NCORR™ stainless steel samples were processed using conditions that represent embodiments of the present disclosure (conditions A through H, as shown inFIGS.6A,6B,7A,7B,8A, and8B) as follows:Condition A=cold working (deformation at room temperature)+low pressure carburizing 1 hr at 500° C.Condition B=cold working (deformation at room temperature)+low pressure carburizing 4 hr at 550° C.Condition C=cold working (warm) (deformation at 1200° F.)+low pressure carburizing 4 hr at 550° C.Condition D=cold working (deformation at room temperature)+low pressure carburizing 16 hr at 550° C.Condition E=cold working (warm) (deformation at 1200° F.)+low pressure carburizing 16 hr at 550° C.Condition F=cold working (deformation at room temperature)+low pressure carburizing 4 hr at 750° C.Condition G=cold working (warm) (deformation at 1200° F.)+low pressure carburizing 4 hr at 750° C.Condition H=cold working (deformation at room temperature)+low pressure carburizing 5 hr at 960° C.

FIG.6Ais a graph illustrating the microhardness (hardness according to Vickers (HV)) of the surface layer of samples of BioDur® 108 stainless steel after five different processing conditions: conditions D, E, F, G, and H. As shown inFIG.6A, the bulk hardness is about 400 HV and the peak hardness at the surface ranges between at least 510 HV and at least 850 HV depending on the processing conditions.FIG.6Bshows the amount of carbon in solution in the surface layer of samples of BioDur® 108 stainless steel after four different processing conditions: conditions A, B, G and H. The carbon level is close to 0.10 wt. % in the bulk and ranges from 0.50 wt. % to 3.65 wt. % in the surface layer depending on the processing conditions.FIG.6Cincludes light optical micrographs showing the visible case layer of some conditions as shown inFIG.6A. The light optical micrographs inFIG.6Cwere taken after etching with waterless Kalling's etchant (conventional mixture of acids used to reveal the alloy microstructure) and show the case surface layer (in brighter tone) and the bulk (darker tone). As shown inFIG.6C, the thickness of the visible case surface layer is about 20-25 μm (condition A and condition B), 40-50 μm (condition D), 70-80 μm (condition F) or 200-300 μm (condition H).

FIG.7Ais a graph illustrating the microhardness (HV) of the surface layer of samples of BioDur® 734 stainless steel processed according to four processing conditions: conditions D, E, F, and G. The bulk hardness is about 350 HV to 400 HV. The hardness of the case layer ranges between 500 HV and 900 HV depending on the processing conditions.FIG.7Bis a graph illustration the carbon composition of the surface layer of samples of BioDur® 734 stainless steel processed according to two processing conditions: conditions D and G. The carbon composition peak in the surface layer ranges between 0.90 wt. % and 3.20 wt. %.FIG.7Cincludes light optical micrographs showing the visible case surface layer formed after case hardening in accordance with conditions as shown inFIG.7AandFIG.7B. As shown inFIG.7C, the case surface layer thickness is 30 to 40 μm (condition D and condition E) or 50 μm to 60 μm (condition F and condition G).

FIG.8Ais a graph illustrating the microhardness (HV) of the surface layer of samples of NCORR™ stainless steel alloy processed according to two conditions: condition F (cold-worked (deformation at room temperature)+carburizing 4 hr at 750° C.) and condition G (cold-worked (warm-worked) (deformation at 1200° F.)+carburizing 4 hr at 750° C.). The bulk hardness is about 350-400 HV and the peak hardness at the surface reached 850 HV to 900 HV.FIG.8Bis a graph illustration the carbon composition of the surface layer of samples of NCORR™ stainless steel processed according to two processing conditions: conditions F and G. The carbon composition peak in the surface layer ranges between 4.10 wt. % and 4.60 wt. %.FIG.8Cincludes light optical micrographs showing the visible case surface layer of each condition illustrated inFIG.8AandFIG.8B. As shown inFIG.8C, the case surface layer thickness is about 50 μm to 70 μm (for both conditions).

All references, issued patents and patent applications cited within the body of the specification are hereby incorporated by reference in their entirety, for all purposes.

While the present invention has been described herein in detail in relation to one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements; the present invention being limited only by the claims appended hereto and the equivalents thereof.