Patent ID: 8602290

Claim:
A method for bonding a porous tantalum structure to a substrate, comprising: providing a substrate comprising cobalt or a cobalt-chromium alloy; providing a porous tantalum structure; applying an interlayer consisting essentially of at least one of hafnium, manganese, niobium, palladium, zirconium, titanium, or alloys or combinations thereof to a surface of the porous tantalum structure, wherein the interlayer is applied to the surface by at least one of thermal spraying, plasma spraying, electron beam deposition, laser deposition, chemical vapor deposition, or electrodeposition; positioning the substrate in contact with the interlayer thereby forming an assembly, wherein the interlayer is between the substrate and the porous tantalum structure; and applying heat and pressure to the assembly for a time sufficient to concurrently achieve solid-state diffusion between the substrate and the interlayer and solid-state diffusion between the interlayer and the porous tantalum structure.