Method of providing a zirconium surface and resulting product

• US 9,764,061 B2
• Filed: 03/02/2016
• Issued: 09/19/2017
• Est. Priority Date: 09/16/2004
• Status: Active Grant

• Current Assignee: Smith & Nephew Incorporated (Smith & Nephew PLC)
• Original Assignee: Smith & Nephew Incorporated (Smith & Nephew PLC)
• Inventors: Hunter, Gordon, Jani, Shilesh, Pawar, Vivek
• Primary Examiner(s): STEWART, ALVIN J
• Application Number:
  US15/058,425
• Publication Number:
  US 20160175484A1
• Time in Patent Office: 566 Days
• Field of Search: 623 235, 623 2354, 623 2032, 623 2356, 623 2014, 623 2015, 623 224, 623 2311, 623 2339, 623 2353
• CPC Class Codes: A61F 2/30 Joints
• CPC Class Codes: A61F 2002/30024 differing in coefficient of friction
• CPC Class Codes: A61F 2002/30026 differing in wear resistance
• CPC Class Codes: A61L 27/306 Other specific inorganic materials not covered by A61L27/303 - A61L27/32
• CPC Class Codes: C22C 45/10 with molybdenum, tungsten, niobium, tantalum, titanium, or zirconium or Hf as the major constituent
• CPC Class Codes: C23C 30/00 Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process C23C26/00, C23C28/00 take precedence
• CPC Class Codes: C23C 8/02 Pretreatment of the material to be coated C23C8/04 takes precedence
• CPC Class Codes: C23C 8/10 Oxidising

Abstract

A coating of blue-black or black zirconium of uniform and controlled thickness on a zirconium or zirconium alloy material is accomplished through the treatment of an amorphous zirconium or zirconium alloy substrate, which may have an altered surface roughness. The treatment of amorphous zirconium or zirconium alloy substrates includes oxidation of the substrates. A zirconium coating of uniform and controlled thickness is especially useful in various applications because the uniformly thick zirconium surface of controlled depth provide a barrier against implant corrosion caused by ionization of the metal substrates.

Claims

1. An article of manufacture comprising:

a zirconium or zirconium alloy having an amorphous structure; and

a surface layer of blue-black or black zirconium oxide on at least a portion of the zirconium or zirconium alloy, wherein the surface layer has a substantially uniform thickness.

2. The article of claim 1, wherein the portion of the zirconium or zirconium alloy further comprises an altered surface roughness.

3. The article of claim 2, wherein said altered surface roughness comprises a surface roughness (Ra) in a range of about 3 microinches to about 25 microinches.

4. The article of claim 1, wherein the oxidized surface layer is formed by oxidation of the zirconium or zirconium alloy.

5. The article of claim 1, wherein said surface layer has a thickness of up to about 20 microns.

6. A component having a durable, wear-resistant and corrosion-resistant surface, comprising:

a substrate comprising a zirconium or zirconium alloy having an amorphous structure; and

a surface layer of blue-black or black oxidized zirconium on at least a portion of the substrate, the surface layer of oxidized zirconium formed by oxidation of the zirconium or zirconium alloy, wherein the surface layer has a substantially uniform thickness.

7. The component of claim 6, wherein the zirconium or zirconium alloy comprises an altered surface roughness prior to the oxidation.

8. The component of claim 7, wherein said altered surface roughness comprises a surface roughness (Ra) in a range of about 3 microinches to about 25 microinches.

9. The component of claim 6, wherein said surface layer has a thickness of up to about 20 microns.

10. A method for producing a component having a durable, wear-resistant and corrosion-resistant surface, comprising:

providing a substrate comprising a zirconium or zirconium alloy having an amorphous structure; and

oxidizing a surface of the substrate under conditions operable to produce a substantially uniform thickness coating of blue-black or black zirconium oxide on the substrate.

11. The method of claim 10, further comprising, before the oxidizing, altering a surface roughness of the zirconium or zirconium alloy.

12. The method of claim 11, wherein the altering comprises altering to a surface roughness (Ra) in the range of about 3 microinches to about 25 microinches.

13. The method of claim 11, wherein the altering the surface roughness comprises an abrasive surface preparation process comprising an action selected from the group consisting of grinding, buffing, mass finishing, vibratory finishing and any combination thereof.

14. The method of claim 10, wherein the oxidizing comprises the use of air as an oxidant.

15. The method of claim 10, wherein the oxidizing comprises the use of oxygen as an oxidant.

16. The method of claim 10, wherein the zirconium or zirconium alloy comprises about 0.3 percent oxygen by weight.

17. The method of claim 10, wherein said oxidizing comprises furnace oxidation with oxygen at a temperature in a range of about 900 degrees F. to 1300 degrees F.

18. The method of claim 10, wherein said oxidizing comprises salt-bath oxidation with at least one salt selected from the group consisting of chlorides, nitrates, cyanides, and a combination thereof.