JP2008001942A - POROUS Co-BASED ALLOY SINTERED COATING MATERIAL AND ITS MANUFACTURING METHOD - Google Patents
POROUS Co-BASED ALLOY SINTERED COATING MATERIAL AND ITS MANUFACTURING METHOD Download PDFInfo
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- 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
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2/30767—Special external or bone-contacting surface, e.g. coating for improving bone ingrowth
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- 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
- A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
- A61F2/02—Prostheses implantable into the body
- A61F2/30—Joints
- A61F2002/30001—Additional features of subject-matter classified in A61F2/28, A61F2/30 and subgroups thereof
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Abstract
Description
この発明は、基材に、高強度と高延性をもつ焼結被覆層を形成した多孔質Ｃｏ基合金焼結被覆材に関するものであって、特に、かかる多孔質Ｃｏ基合金焼結被覆材は、人工関節を始めとするインプラント用材料として用いる場合に適する。 The present invention relates to a porous Co-based alloy sintered coating material in which a sintered coating layer having high strength and high ductility is formed on a base material. Suitable for use as an implant material including an artificial joint.
Ｃｏ基合金、例えばＣｏ−２９質量％Ｃｒ−６質量％Ｍｏ合金で代表されるＣｏＣｒＭｏ合金は、強度および耐食性に優れるため、人工股関節を始めとするインプラント用材料に使用されている。 Co-based alloys, such as CoCrMo alloys represented by Co-29 mass% Cr-6 mass% Mo alloys, are excellent in strength and corrosion resistance, and are therefore used in implant materials including artificial hip joints.
ＣｏＣｒＭｏ合金をインプラント用材料として人体に埋入する場合、生体との結合力を高めるため、例えば球形のＣｏＣｒＭｏ粉末でＣｏＣｒＭｏ合金基材の表面をコーティングした後に焼結して、図１に示すように、表面凹凸を形成した焼結被覆層１０３で基材１０２の表面を被覆することにより形成されるインプラント用材料１０１と生体組織（図示せず）との接触面積を上昇させるような表面処理を施すことが一般に行われている。 When a CoCrMo alloy is embedded in a human body as an implant material, in order to increase the bonding force with a living body, for example, the surface of a CoCrMo alloy base material is coated with a spherical CoCrMo powder and then sintered, as shown in FIG. Then, a surface treatment is performed to increase the contact area between the implant material 101 formed by coating the surface of the base material 102 with the sintered coating layer 103 having surface irregularities and a living tissue (not shown). It is generally done.
しかしながら、球形のＣｏＣｒＭｏ粉末を用いた焼結被覆層は、球形の粉末同士が単に拡散接合して形成されたものであるため、粉末同士間の接触面積が小さく、その結果として、焼結被覆層自体の強度は低い。つまり、焼結被覆層による基材表面の被覆により、焼結被覆層と生体組織との密着強度は向上するが、焼結被覆層自体の強度が低いため、インプラント埋入後に、焼結被覆層の内部での破壊、若しくは焼結被覆層と基材との間で破壊が生じやすいという問題があった。 However, since the sintered coating layer using spherical CoCrMo powder is formed by simply diffusion-bonding spherical powders, the contact area between the powders is small, and as a result, the sintered coating layer Its strength is low. That is, the adhesion strength between the sintered coating layer and the living tissue is improved by coating the surface of the substrate with the sintered coating layer, but the strength of the sintered coating layer itself is low. There has been a problem that breakage tends to occur inside or between the sintered coating layer and the substrate.
また、本発明者らのうちの一人は、生体適合性Ｃｏ基合金として特許文献１において提案した。特許文献１に記載のＣｏ基合金は、鋳造で製造したバルク材を用い、その組織を、熱処理を施してε単相組織に調整することにより、延性能が極めて高くなることを利用し、耐磨耗性、疲労強度を飛躍的に改善したものであるが、このＣｏ基合金は、鋳造材からなるため、表面凹凸が少なく、生体組織に対する密着強度の点で十分ではないという問題を有する。
この発明の目的は、基材上に、所定の組成および条件でＣｏ基合金焼結被覆層を形成することにより、特に人工股関節を始めとするインプラント用材料に使用した場合における、生体組織との密着強度が高く、しかも、焼結被覆層の内部での破壊、若しくは焼結被覆層と基材との間で破壊を有効に防止できる多孔質Ｃｏ基合金焼結被覆材を提供することにある。 An object of the present invention is to form a Co-based alloy sintered coating layer on a base material with a predetermined composition and conditions, so that a living tissue in particular when used as an implant material such as an artificial hip joint is used. An object of the present invention is to provide a porous Co-based alloy sintered coating material having high adhesion strength and capable of effectively preventing destruction inside the sintered coating layer or between the sintered coating layer and the substrate. .
上記目的を達成するため、この発明の要旨は以下のとおりである。
(Ｉ) ＣｏＣｒＭｏ合金からなる基材と、該基材の表面に形成され、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有するとともに、Ｔｉ，Ｚｒ，ＮｂおよびＴａの中から選択される一種または二種以上を合計で０．０５〜５質量％含有し、残部が実質的にＣｏからなる組成をもち、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層とを有することを特徴とする多孔質Ｃｏ基合金焼結被覆材（第１発明）。
In order to achieve the above object, the gist of the present invention is as follows.
(I) A base material made of a CoCrMo alloy, formed on the surface of the base material, containing Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, and among Ti, Zr, Nb and Ta Porous Co-based alloy firing containing a total of 0.05 to 5% by mass of selected one or more types, the balance being substantially composed of Co, and a porosity in the range of 5 to 40% A porous Co-based alloy sintered coating material comprising a binder coating layer (first invention).
（ＩＩ）ＣｏＣｒＭｏ合金からなる基材と、該基材の表面に形成され、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有するとともに、Ｃ：０．０１〜１質量％含有し、残部が実質的にＣｏからなる組成をもち、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層とを有することを特徴とする多孔質Ｃｏ基合金焼結被覆材（第２発明）。 (II) A base material made of a CoCrMo alloy, formed on the surface of the base material, containing Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, and C: 0.01 to 1% by mass And a porous Co-based alloy sintered coating characterized by having a porous Co-based alloy sintered coating layer having a composition substantially consisting of Co and a porosity in the range of 5 to 40% Material (second invention).
（ＩＩＩ）ＣｏＣｒＭｏ合金からなる基材と、該基材の表面に形成され、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有するとともに、Ｎ：０．０１〜２質量％含有し、残部が実質的にＣｏからなる組成をもち、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層とを有することを特徴とする多孔質Ｃｏ基合金焼結被覆材（第３発明）。 (III) A base material made of a CoCrMo alloy, formed on the surface of the base material, containing Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, and N: 0.01 to 2% by mass And a porous Co-based alloy sintered coating characterized by having a porous Co-based alloy sintered coating layer having a composition substantially consisting of Co and a porosity in the range of 5 to 40% Material (third invention).
（ＩＶ） Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有し、残部が実質的にＣｏからなる組成をもつ合金粉末に、Ｔｉ，Ｚｒ，ＮｂおよびＴａの中から選択される一種または二種以上の結合強化粉末を添加し、これらの粉末を混合して混合粉末を調合する工程と、この調合した混合粉末を、ＣｏＣｒＭｏ合金からなる基材の表面上に付着させて混合粉末被覆層を形成する工程と、前記混合粉末被覆層を、真空雰囲気下、負荷応力を１０〜８０ＭＰａとし、８００〜１０００℃の温度範囲で焼結する低温焼結工程と、前記焼結された混合粉末被覆層を、さらに、温度：１０５０〜１２５０℃および１０−３Ｐａ以下の真空雰囲気にて焼結して、基材の表面に、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層を形成する高温焼結工程とを有することを特徴とする多孔質Ｃｏ基合金焼結被覆材の製造方法（第４発明）。 (IV) An alloy powder having a composition containing Cr: 20 to 34% by mass and Mo: 1 to 10% by mass and the balance being substantially made of Co is selected from Ti, Zr, Nb, and Ta. A step of adding one or two or more kinds of bond strengthening powders, mixing these powders to prepare a mixed powder, and adhering the prepared mixed powder onto the surface of a base material made of a CoCrMo alloy. A step of forming a coating layer, a low-temperature sintering step of sintering the mixed powder coating layer in a temperature range of 800 to 1000 ° C. under a load atmosphere of 10 to 80 MPa in a vacuum atmosphere, and the sintered mixture The powder coating layer is further sintered in a vacuum atmosphere at a temperature of 1050 to 1250 ° C. and 10 −3 Pa or less, and a porous Co base having a porosity of 5 to 40% on the surface of the substrate Forming a sintered alloy coating layer That high-temperature sintering process and a porous Co based method for producing alloy sintered coating material and having a (fourth invention).
（Ｖ）Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有し、残部が実質的にＣｏからなる組成をもつ合金粉末に、炭素粉末を添加し、これらの粉末を混合して混合粉末を調合する工程と、この調合した混合粉末を、ＣｏＣｒＭｏ合金からなる基材の表面上に付着させて混合粉末被覆層を形成する工程と、前記混合粉末被覆層を、真空雰囲気下、負荷応力を１０〜８０ＭＰａとし、８００〜１０００℃の温度範囲で焼結する低温焼結工程と、前記焼結された混合粉末被覆層を、さらに、温度：１０５０〜１２５０℃および１０−３Ｐａ以下の真空雰囲気にて焼結して、基材の表面に、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層を形成する高温焼結工程とを有することを特徴とする多孔質Ｃｏ基合金焼結被覆材の製造方法（第５発明）。 (V) Carbon powder is added to an alloy powder containing Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, with the balance being substantially made of Co, and these powders are mixed. A step of preparing a mixed powder, a step of forming the mixed powder coating layer by adhering the prepared mixed powder on the surface of a substrate made of a CoCrMo alloy, and applying the mixed powder coating layer under a vacuum atmosphere A low-temperature sintering step in which the stress is 10 to 80 MPa and sintering is performed at a temperature range of 800 to 1000 ° C., and the sintered mixed powder coating layer is further processed at a temperature of 1050 to 1250 ° C. and 10 −3 Pa or less. And a high-temperature sintering step of forming a porous Co-based alloy sintered coating layer having a porosity of 5 to 40% on the surface of the base material by sintering in a vacuum atmosphere. Of porous Co-based alloy sintered coating Production method (fifth invention).
（ＶＩ）Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有し、残部が実質的にＣｏからなる組成をもつ合金粉末を、ＣｏＣｒＭｏ合金からなる基材の表面上に付着させて合金粉末被覆層を形成する工程と、前記合金粉末被覆層を、窒素雰囲気下、負荷応力を１０〜８０ＭＰａとし、８００〜１０００℃の温度範囲で窒化すると同時に焼結する低温焼結工程と、前記焼結された合金粉末被覆層を、さらに、温度：１０５０〜１２５０℃および１０−３Ｐａ以下の真空雰囲気にて焼結して、基材の表面に、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層を形成する高温焼結工程とを有することを特徴とする多孔質Ｃｏ基合金焼結被覆材の製造方法（第６発明）。 (VI) An alloy powder containing 20% to 34% by mass of Cr and 1% to 10% by mass of Mo and having the balance substantially consisting of Co is deposited on the surface of the base material consisting of CoCrMo alloy. A step of forming an alloy powder coating layer, a low temperature sintering step of sintering the alloy powder coating layer in a nitrogen atmosphere at a load stress of 10 to 80 MPa and nitriding at a temperature range of 800 to 1000 ° C. The sintered alloy powder coating layer is further sintered in a vacuum atmosphere at a temperature of 1050 to 1250 ° C. and 10 −3 Pa or less, and the porosity of the base material surface is in the range of 5 to 40%. A high-temperature sintering step for forming a porous Co-based alloy sintered coating layer (Sixth invention).
この発明によれば、基材上に、所定の組成および条件でＣｏ基合金焼結被覆層を形成することにより、特に人工股関節を始めとするインプラント用材料に使用した場合、生体組織との十分な密着強度をもち、しかも、焼結被覆層の内部での破壊、若しくは焼結被覆層と基材との間で破壊を有効に防止できる多孔質Ｃｏ基合金焼結被覆材の提供が可能になった。 According to the present invention, when a Co-based alloy sintered coating layer is formed on a base material with a predetermined composition and conditions, it is sufficient for living tissue, particularly when used for implant materials such as artificial hip joints. It is possible to provide a porous Co-based alloy sintered coating material that has excellent adhesion strength and that can effectively prevent fracture inside the sintered coating layer or between the sintered coating layer and the substrate. became.
また、基材上に形成される従来のＣｏＣｒＭｏ焼結被覆層は、強度向上のためには、高温でかつ長時間の熱処理を行うことにより、金属元素の拡散を促進させて粉末接触部を拡大させる必要があったが、本発明では、長時間で拡散処理を行なうことなく、Ｃｏ基合金焼結被覆層の高強度化および高延性化の両立を実現した。これにより、人工股関節固定部における多孔質Ｃｏ基合金焼結被覆層の強度を改善することが可能となり、結果として、人工股関節の使用寿命の一層の長期化が可能になる。 In addition, the conventional CoCrMo sintered coating layer formed on the base material has a high-temperature and long-time heat treatment to enhance the strength, thereby promoting the diffusion of metal elements and expanding the powder contact area. However, in the present invention, both high strength and high ductility of the Co-based alloy sintered coating layer were realized without performing diffusion treatment for a long time. As a result, the strength of the porous Co-based alloy sintered coating layer in the artificial hip joint fixing portion can be improved, and as a result, the service life of the artificial hip joint can be further extended.
次に、この発明に従う実施形態について、図面を参照しながら以下で説明する。
図２は、この発明に従う多孔質Ｃｏ基合金焼結被覆材の表面を平らに研磨したときのＳＥＭ（走査型電子顕微鏡）写真である。
Next, an embodiment according to the present invention will be described below with reference to the drawings.
FIG. 2 is an SEM (scanning electron microscope) photograph when the surface of the porous Co-based alloy sintered coating material according to the present invention is polished flat.
図２に示す多孔質Ｃｏ基合金焼結被覆層は、ＣｏＣｒＭｏ合金からなる基材表面に形成され、結合強化粉末としてＴｉを適用したものであって、気孔率が約２８％、すなわち、５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層である。図２中、大径円状のものがＣｏＣｒＭｏ合金で、矢印で示した円状表面の薄膜状のものがＴｉであり、その他が気孔である。 The porous Co-based alloy sintered coating layer shown in FIG. 2 is formed on a substrate surface made of a CoCrMo alloy and applied with Ti as a bond reinforcing powder, and has a porosity of about 28%, that is, 5 to 5%. It is a porous Co-based alloy sintered coating layer in the range of 40%. In FIG. 2, the large-diameter circular shape is a CoCrMo alloy, the thin-film shape having a circular surface indicated by an arrow is Ti, and the others are pores.
前記所定の組成は、第１発明が、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有するとともに、Ｔｉ，Ｚｒ，ＮｂおよびＴａの中から選択される一種または二種以上を合計で０．０５〜５質量％含有し、残部が実質的にＣｏからなる組成であり、第２発明が、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有するとともに、Ｃ：０．０１〜１質量％含有し、残部が実質的にＣｏからなる組成であり、そして、第３発明が、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有するとともに、Ｎ：０．０１〜２質量％含有し、残部が実質的にＣｏからなる組成である。 In the predetermined composition, the first invention contains Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, and at least one selected from Ti, Zr, Nb and Ta. The total content is 0.05 to 5% by mass, and the balance is substantially composed of Co. The second invention contains Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, and C : 0.01 to 1% by mass, with the balance being substantially composed of Co, and the third invention contains Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, N: A composition containing 0.01 to 2% by mass with the balance being substantially Co.
第１〜第３発明は、いずれも多孔質Ｃｏ基合金焼結被覆層中に、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有するＣｏ基合金、具体的にはＣｏ−Ｃｒ−Ｍｏ−Ｘ合金（Ｘ：Ｔｉ，Ｚｒ，ＮｂおよびＴａの中から選択される一種または二種以上、ＣまたはＮ成分）である。 In any of the first to third inventions, a Co-based alloy containing Cr: 20 to 34 mass% and Mo: 1 to 10 mass% in a porous Co-based alloy sintered coating layer, specifically Co— Cr—Mo—X alloy (X: one or more selected from Ti, Zr, Nb and Ta, C or N component).
焼結被覆層の材質をＣｏ基合金に限定する理由は、基材であるＣｏＣｒＭｏ合金の汎用品との相性がよいためである。 The reason for limiting the material of the sintered coating layer to the Co-based alloy is that it is compatible with a general-purpose CoCrMo alloy as a base material.
Ｃｒ含有量を２０〜３４質量％に限定する理由は、２０質量％未満だと、耐食性が劣化するという問題があるからであり、３４質量％超えだと、脆性的になる という問題があるからである。 The reason for limiting the Cr content to 20 to 34% by mass is that if it is less than 20% by mass, there is a problem that the corrosion resistance deteriorates, and if it exceeds 34% by mass, there is a problem that it becomes brittle. It is.
Ｍｏ含有量を１〜１０質量％に限定する理由は、１質量％未満だと、耐食性が劣化するという問題があるからであり、１０質量％超えだと、脆性的になるという問題があるからである。 The reason for limiting the Mo content to 1 to 10% by mass is that if it is less than 1% by mass, there is a problem that the corrosion resistance deteriorates, and if it exceeds 10% by mass, there is a problem that it becomes brittle. It is.
また、第１発明では、上記Ｘ成分が、Ｔｉ，Ｚｒ，ＮｂおよびＴａの中から選択される一種または二種以上であり、粉末結合部分にＣｏＣｒＭｏとＴｉ，Ｚｒ，Ｎｂおよび／またはＴａとが反応してこれらの合金層が形成されることにより、強度および延性を向上させる点で、Ｔｉ，Ｚｒ，ＮｂおよびＴａの中から選択される一種または二種以上を、合計で０．０５〜５質量％含有させる。０．０５質量％未満だと、本発明の効果を奏しないという問題があるからであり、５質量％超えだと、脆性的になるという問題があるからである。 In the first invention, the X component is one or more selected from Ti, Zr, Nb and Ta, and CoCrMo and Ti, Zr, Nb and / or Ta are contained in the powder-bonded portion. By forming these alloy layers by reaction, one or two or more selected from Ti, Zr, Nb and Ta are added in a total amount of 0.05 to 5 in terms of improving strength and ductility. It is contained by mass%. This is because if it is less than 0.05% by mass, there is a problem that the effect of the present invention is not achieved, and if it exceeds 5% by mass, there is a problem that it becomes brittle.
さらに、第２発明では、上記Ｘ成分がＣ成分であり、ネック部に炭化物が形成されることにより、強度及び延性を向上させる点で、Ｃを０．０１〜１質量％含有させる。Ｃ含有量が０．０１質量％未満だと、本発明の効果を奏しないという問題があるからであり、１質量％超えだと、脆性的になるという問題があるからである。 Furthermore, in 2nd invention, said X component is C component, and 0.01-1 mass% of C is contained by the point which improves intensity | strength and ductility by forming a carbide | carbonized_material in a neck part. This is because if the C content is less than 0.01% by mass, the effect of the present invention is not achieved, and if it exceeds 1% by mass, there is a problem that it becomes brittle.
さらにまた、第３発明では、上記Ｘ成分がＮ成分であり、ＣｏＣｒＭｏ合金中にＮが固溶されることにより固溶強化され、強度および延性を向上させる点で、Ｎを０．０１〜２質量％含有させる。Ｎ含有量が０．０１質量％未満だと、本発明の効果を奏しないという問題があるからであり、２質量％超えだと、脆性的になるという問題があるからである。 Furthermore, in the third invention, the X component is an N component, and N is dissolved in a CoCrMo alloy to be strengthened by solid solution, thereby improving the strength and ductility. It is contained by mass%. This is because if the N content is less than 0.01% by mass, there is a problem that the effect of the present invention is not achieved, and if it exceeds 2% by mass, there is a problem that it becomes brittle.
加えて、第１〜第３発明とも、気孔率を５〜４０％の範囲に限定した理由は、５％未満だと、焼結体特有の表面凹凸を十分に形成することができなくなるからであり、また、４０％超えだと、十分な強度が得られず、焼結被覆層の内部での破壊、若しくは焼結被覆層と基材との間で破壊が生じやすくなるからである。 In addition, in both the first to third inventions, the reason for limiting the porosity to the range of 5 to 40% is that if it is less than 5%, the surface unevenness peculiar to the sintered body cannot be sufficiently formed. In addition, if it exceeds 40%, sufficient strength cannot be obtained, and breakage easily occurs inside the sintered coating layer or between the sintered coating layer and the substrate.
そして、第１〜第３発明の多孔質Ｃｏ基合金焼結被覆材はいずれも、Ｃｏ基合金焼結被覆層が上記組成を有することにより、従来の多孔質ＣｏＣｒＭｏ合金焼結被覆層に比べて、強度および延性の双方を格段に向上させることができ、その結果、例えば、人工股関節を始めとするインプラント用材料に使用した場合、生体組織との十分な密着強度をもち、しかも、焼結被覆層の内部での破壊、若しくは焼結被覆層と基材との間で破壊を有効に防止することができる。 The porous Co-based alloy sintered coating materials of the first to third inventions all have a composition as described above, so that the Co-based alloy sintered coating layer has the above composition, compared with the conventional porous CoCrMo alloy sintered coating layer. Therefore, both strength and ductility can be remarkably improved. As a result, for example, when used as an implant material such as an artificial hip joint, it has a sufficient adhesion strength with a living tissue, and also has a sintered coating. Breakage inside the layer or breakage between the sintered coating layer and the substrate can be effectively prevented.
従来の多孔質ＣｏＣｒＭｏ合金焼結被覆材は、Ｃｏ，Ｃｒ，Ｍｏの合金粉末を、基材の表面上に付着させた後、真空雰囲気にて付着させたＣｏＣｒＭｏ合金粉末を焼結する方法によって作製される。しかし、この方法では、粉末結合部の大きさは、Ｃｏ，ＣｒおよびＭｏの拡散による原子の移動に律速されるため、結合部の成長には高温（例えば１２００℃以上）かつ長時間（例えば１０ｈ以上）の熱処理が必要になる。 A conventional porous CoCrMo alloy sintered coating material is produced by a method of sintering CoCrMo alloy powder deposited in a vacuum atmosphere after depositing Co, Cr, Mo alloy powder on the surface of the substrate. Is done. However, in this method, the size of the powder bonding portion is limited by the movement of atoms due to diffusion of Co, Cr, and Mo. Therefore, the growth of the bonding portion is performed at a high temperature (for example, 1200 ° C. or more) and for a long time (for example, 10 h). The above heat treatment is required.
これに対し、本発明では、ＣｏＣｒＭｏに加えて、第１発明ではＴｉ，Ｚｒ，ＮｂおよびＴａの中から選択される一種または二種以上を合計で０．０５〜５質量％含有させ、第２発明ではＣ：０．０１〜１質量％含有させ、第３発明ではＮ：０．０１〜２質量％含有させることにより、第１発明では粉末結合部分にＣｏＣｒＭｏとＴｉ，Ｚｒ，Ｎｂおよび／またはＴａとが反応してこれらの合金層が形成され、第２発明ではネック部に炭化物が形成され、第３発明では固溶強化され、結果として、いずれも発明においても、従来に比べて、比較的低温（具体的には１０００℃以下）かつ短時間（例えば１０ｈ未満）で低温焼結を行った後に高温焼結処理（具体的には、１０５０〜１２５０℃で２時間程度）により完結することができるので、簡便かつ安価に、高強度および高延性を有する多孔質Ｃｏ基合金焼結被覆層を形成することができる。 On the other hand, in the present invention, in addition to CoCrMo, the first invention contains one or more selected from Ti, Zr, Nb and Ta in a total amount of 0.05 to 5% by mass. In the invention, C: 0.01 to 1% by mass, and in the third invention, N: 0.01 to 2% by mass, and in the first invention, CoCrMo and Ti, Zr, Nb and / or These alloy layers are formed by reaction with Ta, carbide is formed in the neck portion in the second invention, and solid solution strengthening is performed in the third invention. As a result, both of the inventions are compared with the conventional ones. Complete by low temperature sintering (specifically 1000 ° C. or less) and low temperature sintering in a short time (for example, less than 10 hours), followed by high temperature sintering treatment (specifically, about 1050 to 1250 ° C. for about 2 hours) So you can Stool and inexpensive, it is possible to form a porous Co based alloy sintered coating layer having a high strength and high ductility.
次に、この発明に従う多孔質Ｃｏ基合金焼結被覆材の製造方法を以下で説明する。 Next, a method for producing a porous Co-based alloy sintered coating material according to the present invention will be described below.
（試験例１−第４発明）
第１発明の多孔質Ｃｏ基合金焼結被覆材を製造するための代表的な方法は、人工関節用合金として、例えばＡＳＴＭ規格のＦ７５合金組成で炭素を含有させない合金組成、すなわち、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有し、残部が実質的にＣｏからなる組成をもつ合金粉末に、Ｔｉ，Ｚｒ，ＮｂおよびＴａの中から選択される一種または二種以上の結合強化粉末を、所定の割合、好適には０．０５〜５質量％の割合で添加し、これらの粉末を混合して混合粉末を調合する（調合工程）。
(Test Example 1-fourth invention)
A typical method for producing the porous Co-based alloy sintered coating material of the first invention is an alloy composition that does not contain carbon, for example, an ASTM standard F75 alloy composition as an alloy for artificial joints, that is, Cr: 20. In an alloy powder having a composition containing ~ 34% by mass and Mo: 1% by mass to 10%, and the balance being substantially made of Co, one or more selected from Ti, Zr, Nb and Ta A bond-strengthening powder is added at a predetermined ratio, preferably 0.05 to 5% by mass, and these powders are mixed to prepare a mixed powder (preparation step).
合金粉末の粒径は、５０〜５００μｍであることが好ましい。本発明では、合金粉末の粒径を５０〜５００μｍとすることにより、本発明において必須の構成要件とする気孔率５〜４０％を達成することが可能となる。すなわち、合金粉末の粒径が５０μｍ未満だと、気孔率が５％未満となる傾向があり、前記粒径が５００μｍよりも大きいと、気孔率が４０％を超える傾向があり、いずれも生体組織との密着強度が十分に保てなくなるからである。
また、結合強化粉末は、４５〜５００μｍであることが好ましい。
The particle size of the alloy powder is preferably 50 to 500 μm. In the present invention, by setting the particle size of the alloy powder to 50 to 500 μm, it is possible to achieve a porosity of 5 to 40%, which is an essential constituent element in the present invention. That is, when the particle size of the alloy powder is less than 50 μm, the porosity tends to be less than 5%, and when the particle size is larger than 500 μm, the porosity tends to exceed 40%, both of which are biological tissues. This is because the adhesion strength to the surface cannot be maintained sufficiently.
Moreover, it is preferable that a bond reinforcement | strengthening powder is 45-500 micrometers.
次いで、この調合した混合粉末を、ＣｏＣｒＭｏ合金からなる基材の表面上に付着させて混合粉末被覆層を形成する（被覆層形成工程）。 Next, the prepared mixed powder is adhered onto the surface of a base material made of a CoCrMo alloy to form a mixed powder coating layer (coating layer forming step).
また、基材の表面上に混合粉末被覆層を付着させる方法としては、例えば、基材上に単純に混合粉末を直接接触させて付着させる方法や、これらの混合粉末をエタノールのような溶媒に分散させ、この溶媒中に基材を浸漬することにより付着させる方法が挙げられるが、本発明では、かかる方法だけには限定されず、種々の付着方法を採用することができる。 In addition, as a method for attaching the mixed powder coating layer on the surface of the substrate, for example, a method in which the mixed powder is simply brought into direct contact with the substrate and the mixed powder is attached to a solvent such as ethanol. Although the method of making it disperse | distribute and making it adhere | attach by immersing a base material in this solvent is mentioned, in this invention, it is not limited only to this method, Various adhesion methods can be employ | adopted.
被覆層形成工程の後、前記混合粉末被覆層を、下記に示す２段階の焼結工程、すなわち、低温焼結工程と高温焼結工程を行なうことにある。 After the coating layer forming step, the mixed powder coating layer is subjected to the following two-stage sintering process, that is, a low temperature sintering process and a high temperature sintering process.
低温焼結工程は、具体的には、真空雰囲気下、負荷応力を１０〜８０ＭＰａとし、８００〜１０００℃の温度範囲で焼結する。 Specifically, the low-temperature sintering step is performed at a temperature range of 800 to 1000 ° C. under a vacuum atmosphere with a load stress of 10 to 80 MPa.
前記温度を８００〜１０００℃に限定した理由は、８００℃未満だと、粉末同士が結合しないという問題があるからであり、１０００℃超えだと、優位性がなく不経済であるという問題があるからである。 The reason why the temperature is limited to 800 to 1000 ° C. is that when the temperature is less than 800 ° C., there is a problem that the powders are not bonded to each other, and when the temperature exceeds 1000 ° C., there is a problem that there is no advantage and it is uneconomical. Because.
また、前記真空雰囲気に限定した理由は、この低温焼結工程は、混合粉末被覆層が基材に形成されるための前処理としての機能があればよく、そのためには真空の領域で処理することが必要であるからである。なお、前記真空雰囲気における真空度については、本発明では特に限定する必要はない。 The reason for limiting to the vacuum atmosphere is that the low-temperature sintering step only needs to have a function as a pretreatment for forming the mixed powder coating layer on the base material, and for this purpose, the treatment is performed in a vacuum region. Because it is necessary. Note that the degree of vacuum in the vacuum atmosphere is not particularly limited in the present invention.
さらに、前記焼結での負荷応力を１０〜８０ＭＰａに限定した理由は、１０ＭＰａ未満だと、粉末同士が接合しないという問題があるからであり、８０ＭＰａ超えだと、気孔率が小さくなるという問題があるからである。 Furthermore, the reason why the load stress in the sintering is limited to 10 to 80 MPa is that if the pressure is less than 10 MPa, there is a problem that the powders do not join each other, and if it exceeds 80 MPa, the porosity is reduced. Because there is.
また、高温焼結工程は、温度：１０５０〜１２５０℃および１０−３Ｐａ以下の真空雰囲気にて焼結して、基材の表面に、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層を形成する。 The high-temperature sintering step is performed by sintering in a vacuum atmosphere at a temperature of 1050 to 1250 ° C. and 10 −3 Pa or less, and porous Co having a porosity of 5 to 40% on the surface of the substrate. A base alloy sintered coating layer is formed.
前記温度を１０５０〜１２５０℃に限定した理由は、１０５０℃未満だと、脆性的になるという問題があるからであり、１２５０℃超えだと、優位性がなく不経済であるという問題があるからである。 The reason why the temperature is limited to 1050 to 1250 ° C. is that if it is less than 1050 ° C., there is a problem that it becomes brittle, and if it exceeds 1250 ° C., there is a problem that there is no advantage and it is uneconomical. It is.
また、前記真空雰囲気圧を１０-3Ｐａ以下に限定した理由は、１０-3Ｐａ超えだと、コーティング層が酸化するという問題があるからである。 The reason why the vacuum atmospheric pressure is limited to 10 −3 Pa or less is that if it exceeds 10 −3 Pa, the coating layer is oxidized.
なお、前記焼結での負荷応力は、５０ＭＰａとすることが好ましい。５０ＭＰａ超えだと、気孔率が５％よりも小さくなる傾向があるからである。 Note that the load stress in the sintering is preferably 50 MPa. This is because if it exceeds 50 MPa, the porosity tends to be smaller than 5%.
このようにして製造された第１発明の多孔質Ｃｏ基合金焼結被覆材は、焼結時に、Ｔｉ，Ｚｒ，ＮｂおよびＴａの中から選択される一種または二種以上の結合強化粉末が、ＣｏＣｒＭｏの合金粉末と反応することによって、粉末結合部分に合金層が形成される結果、基材表面に、高強度および高延性を有する多孔質Ｃｏ基合金焼結被覆層を形成することができる。 The porous Co-based alloy sintered coating material of the first invention produced in this way has one or two or more types of bond-strengthening powder selected from Ti, Zr, Nb and Ta at the time of sintering. By reacting with the CoCrMo alloy powder, an alloy layer is formed at the powder bonding portion. As a result, a porous Co-based alloy sintered coating layer having high strength and high ductility can be formed on the surface of the substrate.
（試験例２−第５発明）
第２発明の多孔質Ｃｏ基合金焼結被覆材を製造するための代表的な方法は、人工関節用合金として、例えばＡＳＴＭ規格のＦ７５合金組成で炭素を含有させない合金組成、すなわち、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有し、残部が実質的にＣｏからなる組成をもつ合金粉末に、炭素粉末を、所定の割合、好適には０．０１〜１質量％の割合で添加し、これらの粉末を混合して混合粉末を調合する（調合工程）。
(Test Example 2-5 invention)
A representative method for producing the porous Co-based alloy sintered coating material of the second invention is, for example, an alloy composition that does not contain carbon in the F75 alloy composition of the ASTM standard as an alloy for artificial joints, that is, Cr: 20. To 34 mass% and Mo: 1 to 10 mass%, and the alloy powder having a composition substantially consisting of Co, the carbon powder is added in a predetermined proportion, preferably 0.01 to 1 mass%. They are added at a ratio, and these powders are mixed to prepare a mixed powder (preparation step).
合金粉末の粒径は、５０〜５００μｍであることが好ましく、また、炭素粉末は、１００ｎｍ〜１００μｍであることが好ましい。合金粉末の粒径を５０〜５００μｍとしたことの理由は、試験例１−第４発明のところで記載したのと同様である。 The particle diameter of the alloy powder is preferably 50 to 500 μm, and the carbon powder is preferably 100 nm to 100 μm. The reason for setting the particle size of the alloy powder to 50 to 500 μm is the same as that described in Test Example 1-4.
その後は、試験例１と同様の条件で、被覆層形成工程、低温焼結工程および高温焼結工程を行なうことにより、第２発明の多孔質Ｃｏ基合金焼結被覆材を得る。 Thereafter, the porous Co-based alloy sintered coating material of the second invention is obtained by performing the coating layer forming step, the low temperature sintering step and the high temperature sintering step under the same conditions as in Test Example 1.
このようにして製造された多孔質Ｃｏ基合金焼結被覆材は、焼結時に、炭素粉末が、ＣｏＣｒＭｏの合金粉末と反応することによって、ネック部に炭化物が形成される結果、基材表面に、高強度および高延性を有する多孔質Ｃｏ基合金焼結被覆層を形成することができる。 The porous Co-based alloy sintered coating material manufactured in this way has a carbon powder that reacts with the CoCrMo alloy powder during sintering to form carbides in the neck portion. A porous Co-based alloy sintered coating layer having high strength and high ductility can be formed.
（試験例３−第６発明）
第２発明の多孔質Ｃｏ基合金焼結被覆材を製造するための代表的な方法は、人工関節用合金として、例えばＡＳＴＭ規格のＦ７５合金組成で炭素を含有させない合金組成、すなわち、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有し、残部が実質的にＣｏからなる組成をもつ合金粉末を、ＣｏＣｒＭｏ合金からなる基材の表面上に付着させて合金粉末被覆層を形成する（被覆層形成工程）。
(Test Example 3-6 invention)
A typical method for producing the porous Co-based alloy sintered coating material of the second invention is an alloy composition for artificial joints, for example, an ASTM standard F75 alloy composition that does not contain carbon, that is, Cr: 20. An alloy powder coating layer is formed by adhering alloy powder having a composition containing ~ 34 mass% and Mo: 1-10 mass%, with the balance being substantially made of Co, on the surface of a substrate made of CoCrMo alloy. (Coating layer forming step).
次いで、合金粉末被覆層を、窒素雰囲気下、負荷応力を１０〜８０ＭＰａとし、８００〜１０００℃の温度範囲で窒化すると同時に焼結する（低温焼結工程）。 Next, the alloy powder coating layer is sintered at the same time as nitriding in a temperature range of 800 to 1000 ° C. under a nitrogen atmosphere under a load stress of 10 to 80 MPa (low temperature sintering step).
前記温度を８００〜１０００℃に限定した理由は、８００℃未満だと、粉末同士が接合しないという問題があるからであり、１０００℃超えだと、優位性がなく不経済であるという問題があるからである。 The reason why the temperature is limited to 800 to 1000 ° C. is that when the temperature is less than 800 ° C., there is a problem that the powders do not join each other, and when the temperature exceeds 1000 ° C., there is a problem that there is no advantage and it is uneconomical. Because.
また、前記窒素雰囲気に限定した理由は、窒素を合金中に十分固溶させるために必須な要件である。 The reason for limiting to the nitrogen atmosphere is an essential requirement for sufficiently dissolving nitrogen in the alloy.
さらに、前記焼結での負荷応力を１０〜８０ＭＰａに限定した理由は、１０ＭＰａ未満だと、粉末同士が接合しないという問題があるからであり、８０ＭＰａ超えだと、気孔率が小さくなるという問題があるからである。 Furthermore, the reason why the load stress in the sintering is limited to 10 to 80 MPa is that if the pressure is less than 10 MPa, there is a problem that the powders do not join each other, and if it exceeds 80 MPa, the porosity is reduced. Because there is.
その後は、試験例１と同様の条件で高温焼結工程を行なうことにより、第３発明の多孔質Ｃｏ基合金焼結被覆材を得る。 Thereafter, a high-temperature sintering step is performed under the same conditions as in Test Example 1 to obtain the porous Co-based alloy sintered coating material of the third invention.
このようにして製造された第３発明の多孔質Ｃｏ基合金焼結被覆材は、焼結時に、窒素がＣｏＣｒＭｏ合金中に固溶することによって、ＣｏＣｒＭｏ合金焼結層が固溶強化される結果、基材表面に、高強度および高延性を有する多孔質Ｃｏ基合金焼結被覆層を形成することができる。 The porous Co-based alloy sintered coating material of the third invention produced in this way is a result of the solid solution strengthening of the CoCrMo alloy sintered layer due to the solid solution of nitrogen in the CoCrMo alloy during sintering. A porous Co-based alloy sintered coating layer having high strength and high ductility can be formed on the substrate surface.
上述したところは、この発明の実施形態の例を示したにすぎず、請求の範囲において種々の変更を加えることができる。 What has been described above is merely an example of an embodiment of the present invention, and various modifications can be made within the scope of the claims.
（実施例１）
人工関節用合金として、ＡＳＴＭ規格のＦ７５合金組成で炭素を含有させない合金組成、すなわち、平均粒径が３１６μｍのＣｏ−２９質量％Ｃｒ−６質量％Ｍｏ合金粉末に、平均粒径が６５μｍのＴｉを１質量％添加し、これらの粉末を混合して混合粉末を調合し、この調合した混合粉末を、特許文献１に示す鋳造法により製造したＣｏ−２９質量％Ｃｒ−６質量％Ｍｏ−０．０２質量％Ｃからなる基材の表面上に、単純に混合粉末を直接接触させて付着させて混合粉末被覆層を形成し、その後、前記混合粉末被覆層を、真空雰囲気下、負荷応力を４０ＭＰａとし、９５０℃の温度で２時間低温焼結を行ない、次いで、温度：１２７０℃および１０−３Ｐａの以下の真空雰囲気にて、無負荷で２時間の高温焼結を行ない、基材上に、気孔率が２８％である多孔質Ｃｏ基合金焼結被覆層を形成した多孔質Ｃｏ基合金焼結被覆材（実施例１）を作製し、引張強度および破断伸びを測定した。
(Example 1)
As an alloy for artificial joints, an ASTM standard F75 alloy composition containing no carbon, that is, a Co-29 mass% Cr-6 mass% Mo alloy powder having an average grain diameter of 316 μm and Ti having an average grain diameter of 65 μm 1% by mass, mixing these powders to prepare a mixed powder, and preparing this mixed powder by a casting method shown in Patent Document 1, Co-29% by mass Cr-6% by mass Mo-0 The mixed powder coating layer is formed by simply contacting the mixed powder directly on the surface of the base material composed of 0.02 mass% C to form a mixed powder coating layer, and then applying the load stress to the mixed powder coating layer in a vacuum atmosphere. 40 MPa, low temperature sintering is performed at a temperature of 950 ° C. for 2 hours, and then high temperature sintering is performed for 2 hours at a temperature of 1270 ° C. and 10 −3 Pa in the following vacuum atmosphere with no load. And porosity 28% porous Co based alloy sintered coating layer was formed porous Co based alloy sintered coating material was prepared (Example 1) were measured tensile strength and elongation at break.
また、参考のため、基材上に、Ｔｉを含有しない、従来の多孔質Ｃｏ−Ｃｒ−Ｍｏ合金焼結被覆層を形成した、気孔率が２９％である多孔質Ｃｏ基合金焼結被覆材（従来例）についても同様に作製し、引張強度および破断伸びを測定した。図３は、従来の多孔質Ｃｏ基合金焼結被覆材（従来例）の表面を平らに研磨したときのＳＥＭ写真を示したものである。 Further, for reference, a porous Co-based alloy sintered coating material having a porosity of 29%, in which a conventional porous Co—Cr—Mo alloy sintered coating layer containing no Ti is formed on a base material. A (conventional example) was prepared in the same manner, and the tensile strength and elongation at break were measured. FIG. 3 shows an SEM photograph when the surface of a conventional porous Co-based alloy sintered coating material (conventional example) is polished flat.
このように作製した各多孔質Ｃｏ基合金焼結被覆材について、引張強度と破断伸びを測定した。なお、引張強度の測定は、インストロン型引張り試験機により行い、破断伸びの測定は、ひずみゲージにより行った。 The tensile strength and elongation at break were measured for each porous Co-based alloy sintered coating material produced in this way. The tensile strength was measured with an Instron type tensile tester, and the elongation at break was measured with a strain gauge.
その結果、従来例の多孔質Ｃｏ基合金焼結被覆材は、引張強度が１１６ＭＰａおよび破断伸びが０．８％であるのに対し、実施例１の多孔質Ｃｏ基合金焼結被覆材は、引張強度が１７８ＭＰａ（従来例対比５３％増）および破断伸びが３．７％（従来例対比４．６倍）と、高引張強度および高破断伸びを有していた。なお、生体組織に対する密着強度は、表面形状に負うところが大であり、従来技術とこの発明との間には表面形状においては大差がないことから、両者間に生体組織に対する密着強度の差異は認められなかった。 As a result, the porous Co-based alloy sintered coating material of the conventional example has a tensile strength of 116 MPa and a breaking elongation of 0.8%, whereas the porous Co-based alloy sintered coating material of Example 1 is The tensile strength was 178 MPa (up 53% compared to the conventional example) and the elongation at break was 3.7% (4.6 times that of the conventional example). It should be noted that the adhesion strength with respect to the living tissue largely depends on the surface shape, and there is no great difference in the surface shape between the prior art and the present invention. I couldn't.
また、Ｔｉの代わりに、Ｚｒ，ＮｂまたはＴａを０．０５〜５質量％含有させた場合や、Ｔｉ，Ｚｒ，Ｎｂ及びＴａの中から選択される二種以上を合計で０．０５〜５質量％含有させた場合についても、説明は省略したが、引張強度及び破断伸びを測定し、実施例１の多孔質Ｃｏ基合金焼結被覆材と同様な高引張強度及び高破断伸びを有することについても併せて確認した。 Further, when 0.05 to 5% by mass of Zr, Nb or Ta is contained instead of Ti, or a total of two or more selected from Ti, Zr, Nb and Ta is 0.05 to 5 Although the explanation is omitted for the case of containing by mass%, the tensile strength and elongation at break are measured, and have the same high tensile strength and high elongation as the porous Co-based alloy sintered coating material of Example 1. Was also confirmed.
（実施例２）
人工関節用合金として、ＡＳＴＭ規格のＦ７５合金組成で炭素を含有させない合金組成、すなわち、平均粒径が３１６μｍのＣｏ−２９質量％Ｃｒ−６質量％Ｍｏ合金粉末に、平均粒径が２０ｎｍのＣを０．５質量％添加し、これらの粉末を混合して混合粉末を調合し、この調合した混合粉末を、特許文献１に示す鋳造法により製造したＣｏ−２９質量％Ｃｒ−６質量％Ｍｏ−０．０２質量％Ｃからなる基材の表面上に、単純に混合粉末を直接接触させて付着させて混合粉末被覆層を形成し、その後、前記混合粉末被覆層を、真空雰囲気下、負荷応力を４０ＭＰａとし、９５０℃の温度で２時間低温焼結を行ない、次いで、温度：１２００℃および１０−３Ｐａの真空雰囲気にて、無負荷で２時間の高温焼結を行ない、基材上に、気孔率が２７％である多孔質Ｃｏ基合金焼結被覆層を形成した多孔質Ｃｏ基合金焼結被覆材（実施例２）を作製し、引張強度および破断伸びを測定した。
(Example 2)
As an alloy for artificial joints, an ASTM standard F75 alloy composition containing no carbon, that is, a Co-29 mass% Cr-6 mass% Mo alloy powder having an average particle diameter of 316 μm and a C particle having an average particle diameter of 20 nm. 0.5% by mass, and these powders are mixed to prepare a mixed powder, and this prepared mixed powder is produced by the casting method shown in Patent Document 1, Co-29% by mass Cr-6% by mass Mo -A mixed powder coating layer is simply formed by directly contacting and adhering the mixed powder on the surface of a substrate composed of 0.02 mass% C, and then the mixed powder coating layer is loaded under a vacuum atmosphere. Stress is 40 MPa, low temperature sintering is performed at a temperature of 950 ° C. for 2 hours, and then high temperature sintering is performed for 2 hours in a vacuum atmosphere at a temperature of 1200 ° C. and 10 −3 Pa for 2 hours. And porosity is 2 A porous Co-based alloy sintered coating material (Example 2) in which a porous Co-based alloy sintered coating layer of 7% was formed was produced, and the tensile strength and elongation at break were measured.
また、参考のため、基材上に、Ｃを含有しない、従来の多孔質Ｃｏ−Ｃｒ−Ｍｏ合金焼結被覆層を形成した、気孔率が２９％である多孔質Ｃｏ基合金焼結被覆材（従来例）についても同様に作製し、引張強度、破断伸びおよび生体組織に対する密着強度を測定した。 Further, for reference, a porous Co-based alloy sintered coating material having a porosity of 29%, in which a conventional porous Co—Cr—Mo alloy sintered coating layer containing no C is formed on a base material. (Conventional example) was also prepared in the same manner, and tensile strength, elongation at break and adhesion strength to living tissue were measured.
その結果、従来例の多孔質Ｃｏ基合金焼結被覆材は、引張強度が１１６ＭＰａおよび破断伸びが０．８％であるのに対し、実施例２の多孔質Ｃｏ基合金焼結被覆材は、引張強度が１４８ＭＰａ（従来例対比２８％増）および破断伸びが３．８％（従来例対比４．７５倍）と、高引張強度および高破断伸びを有していた。 As a result, the porous Co-based alloy sintered coating material of the conventional example has a tensile strength of 116 MPa and a breaking elongation of 0.8%, whereas the porous Co-based alloy sintered coating material of Example 2 The tensile strength was 148 MPa (28% increase compared to the conventional example) and the elongation at break was 3.8% (4.75 times the conventional example), which had high tensile strength and high elongation at break.
（実施例３）
人工関節用合金として、ＡＳＴＭ規格のＦ７５合金組成で炭素を含有させない合金組成、すなわち、平均粒径が３１６μｍのＣｏ−２９質量％Ｃｒ−６質量％Ｍｏ合金粉末を、特許文献１に示す鋳造法により製造したＣｏ−２９質量％Ｃｒ−６質量％Ｍｏ−０．０２質量％Ｃからなる基材の表面上に、単純に混合粉末を直接接触させて付着させて合金粉末被覆層を形成し、その後、前記合金粉末被覆層を、温度：９５０℃の窒素雰囲気にて、４０ＭＰａの負荷応力で２時間の低温焼結を行ない、次いで、温度：１２００℃および１０−３Ｐａの真空雰囲気にて、 ０ＭＰａの負荷応力で２時間の高温焼結を行ない、基材上に、気孔率が２７％である多孔質Ｃｏ基合金焼結被覆層を形成した多孔質Ｃｏ基合金焼結被覆材（実施例３）を作製し、引張強度および破断伸びを測定した。
(Example 3)
As an alloy for artificial joints, an ASTM standard F75 alloy composition that does not contain carbon, that is, a Co-29 mass% Cr-6 mass% Mo alloy powder having an average particle size of 316 μm, is shown in Patent Document 1. On the surface of the base material made of Co-29 mass% Cr-6 mass% Mo-0.02 mass% C produced by the above, the mixed powder is simply brought into direct contact and adhered to form an alloy powder coating layer, Thereafter, the alloy powder coating layer was sintered at a temperature of 950 ° C. in a nitrogen atmosphere at a load stress of 40 MPa for 2 hours, and then at a temperature of 1200 ° C. and a vacuum atmosphere of 10 −3 Pa. Porous Co-based alloy sintered coating material obtained by performing high-temperature sintering for 2 hours under a load stress of 0 MPa and forming a porous Co-based alloy sintered coating layer having a porosity of 27% on a base material (Example) 3) Zhang strength and elongation at break were measured.
また、参考のため、基材上に、Ｎを含有しない、従来の多孔質Ｃｏ−Ｃｒ−Ｍｏ合金焼結被覆層を形成した、気孔率が２９％である多孔質Ｃｏ基合金焼結被覆材（従来例）についても同様に作製し、引張強度および破断伸びを測定した。 Further, for reference, a porous Co-based alloy sintered coating material having a porosity of 29%, in which a conventional porous Co—Cr—Mo alloy sintered coating layer containing no N is formed on a base material. A (conventional example) was prepared in the same manner, and the tensile strength and elongation at break were measured.
その結果、従来例の多孔質Ｃｏ基合金焼結被覆材は、引張強度が１１６ＭＰａおよび破断伸びが０．８％であるのに対し、実施例３の多孔質Ｃｏ基合金焼結被覆材は、引張強度が１５８ＭＰａ（従来例対比３６％増）および破断伸びが４．０％（従来例対比５倍）と、高引張強度および高破断伸びを有していた。 As a result, the porous Co-based alloy sintered coating material of the conventional example has a tensile strength of 116 MPa and a breaking elongation of 0.8%, whereas the porous Co-based alloy sintered coating material of Example 3 The tensile strength was 158 MPa (an increase of 36% compared to the conventional example) and the elongation at break was 4.0% (5 times that of the conventional example), and the tensile strength and the elongation at break were high.
この発明によれば、基材上に、所定の組成および条件でＣｏ基合金焼結被覆層を形成することにより、特に人工股関節を始めとするインプラント用材料に使用した場合、生体組織との十分な密着強度をもち、しかも、焼結被覆層の内部での破壊、若しくは焼結被覆層と基材との間で破壊を有効に防止できる多孔質Ｃｏ基合金焼結被覆材の提供が可能になった。 According to the present invention, when a Co-based alloy sintered coating layer is formed on a base material with a predetermined composition and conditions, it is sufficient for living tissue, particularly when used for implant materials such as artificial hip joints. It is possible to provide a porous Co-based alloy sintered coating material that has excellent adhesion strength and that can effectively prevent fracture inside the sintered coating layer or between the sintered coating layer and the substrate. became.
また、基材上に形成される従来のＣｏＣｒＭｏ焼結被覆層は、強度向上のためには、高温でかつ長時間の熱処理を行いことにより、金属元素の拡散を促進させて粉末接触部を拡大させる必要があったが、本発明では、長時間で拡散処理を行なうことなく、Ｃｏ基合金焼結被覆層の高強度化および高延性化の両立を実現した。これにより、人工股関節固定部における多孔質Ｃｏ基合金焼結被覆層の強度を改善することが可能となり、結果として、人工股関節の使用寿命の一層の長期化が可能になる。この発明の多孔質Ｃｏ基合金焼結被覆材は、生体毒性の少ない、すなわちより安全で使用寿命の長い、人工股関節、人工膝関節などの医療用デバイスに応用可能である。 In addition, the conventional CoCrMo sintered coating layer formed on the base material has a high temperature and long-time heat treatment to promote the diffusion of metal elements and expand the powder contact area in order to improve strength. However, in the present invention, both high strength and high ductility of the Co-based alloy sintered coating layer were realized without performing diffusion treatment for a long time. As a result, the strength of the porous Co-based alloy sintered coating layer in the artificial hip joint fixing portion can be improved, and as a result, the service life of the artificial hip joint can be further extended. The porous Co-based alloy sintered coating material of the present invention can be applied to medical devices such as artificial hip joints and artificial knee joints that have less biotoxicity, that is, are safer and have a longer service life.
Claims (6)
該基材の表面に形成され、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有するとともに、Ｔｉ，Ｚｒ，ＮｂおよびＴａの中から選択される一種または二種以上を合計で０．０５〜５質量％含有し、残部が実質的にＣｏからなる組成をもち、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層と
を有することを特徴とする多孔質Ｃｏ基合金焼結被覆材。 A substrate made of a CoCrMo alloy;
It is formed on the surface of the substrate and contains Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, and one or more selected from Ti, Zr, Nb and Ta in total A porous Co-based alloy sintered coating layer having a composition of 0.05 to 5% by mass, the balance being substantially made of Co, and a porosity in the range of 5 to 40%. Porous Co-based alloy sintered coating material.
該基材の表面に形成され、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有するとともに、Ｃ：０．０１〜１質量％含有し、残部が実質的にＣｏからなる組成をもち、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層と
を有することを特徴とする多孔質Ｃｏ基合金焼結被覆材。 A substrate made of a CoCrMo alloy;
A composition formed on the surface of the base material, containing Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, C: 0.01 to 1% by mass, and the balance being substantially made of Co. And a porous Co-based alloy sintered coating layer having a porosity in the range of 5 to 40%.
該基材の表面に形成され、Ｃｒ：２０〜３４質量％およびＭｏ：１〜１０質量％を含有するとともに、Ｎ：０．０１〜２質量％含有し、残部が実質的にＣｏからなる組成をもち、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層と
を有することを特徴とする多孔質Ｃｏ基合金焼結被覆材。 A substrate made of a CoCrMo alloy;
A composition formed on the surface of the substrate, containing Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, N: 0.01 to 2% by mass, and the balance being substantially made of Co. And a porous Co-based alloy sintered coating layer having a porosity in the range of 5 to 40%.
この調合した混合粉末を、ＣｏＣｒＭｏ合金からなる基材の表面上に付着させて混合粉末被覆層を形成する工程と、
前記混合粉末被覆層を、真空雰囲気下、負荷応力を１０〜８０ＭＰａとし、８００〜１０００℃の温度範囲で焼結する低温焼結工程と、
前記焼結された混合粉末被覆層を、さらに、温度：１０５０〜１２５０℃および１０−３Ｐａ以下の真空雰囲気にて焼結して、基材の表面に、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層を形成する高温焼結工程と
を有することを特徴とする多孔質Ｃｏ基合金焼結被覆材の製造方法。 An alloy powder containing Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, with the balance being substantially made of Co, is one or two selected from Ti, Zr, Nb and Ta. Adding a bond strengthening powder of seeds or more and mixing these powders to prepare a mixed powder;
A process of forming the mixed powder coating layer by adhering the prepared mixed powder on the surface of a base material made of a CoCrMo alloy;
A low-temperature sintering step in which the mixed powder coating layer is sintered in a temperature range of 800 to 1000 ° C. under a vacuum atmosphere under a load stress of 10 to 80 MPa;
The sintered mixed powder coating layer is further sintered in a vacuum atmosphere at a temperature of 1050 to 1250 ° C. and 10 −3 Pa or less, and the porosity of the base material surface is in the range of 5 to 40%. And a high-temperature sintering step of forming a porous Co-based alloy sintered coating layer, which is a method for producing a porous Co-based alloy sintered coating material.
この調合した混合粉末を、ＣｏＣｒＭｏ合金からなる基材の表面上に付着させて混合粉末被覆層を形成する工程と、
前記混合粉末被覆層を、真空雰囲気下、負荷応力を１０〜８０ＭＰａとし、８００〜１０００℃の温度範囲で焼結する低温焼結工程と、
前記焼結された混合粉末被覆層を、さらに、温度：１０５０〜１２５０℃および１０−３Ｐａ以下の真空雰囲気にて焼結して、基材の表面に、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層を形成する高温焼結工程と
を有することを特徴とする多孔質Ｃｏ基合金焼結被覆材の製造方法。 Carbon powder is added to an alloy powder containing Cr: 20 to 34% by mass and Mo: 1 to 10% by mass, with the balance being substantially made of Co, and these powders are mixed to obtain a mixed powder. The step of blending;
A process of forming the mixed powder coating layer by adhering the prepared mixed powder on the surface of a base material made of a CoCrMo alloy;
A low-temperature sintering step in which the mixed powder coating layer is sintered in a temperature range of 800 to 1000 ° C. under a vacuum atmosphere under a load stress of 10 to 80 MPa;
The sintered mixed powder coating layer is further sintered in a vacuum atmosphere at a temperature of 1050 to 1250 ° C. and 10 −3 Pa or less, and the porosity of the base material surface is in the range of 5 to 40%. And a high-temperature sintering step of forming a porous Co-based alloy sintered coating layer, which is a method for producing a porous Co-based alloy sintered coating material.
前記合金粉末被覆層を、窒素雰囲気下、負荷応力を１０〜８０ＭＰａとし、８００〜１０００℃の温度範囲で窒化すると同時に焼結する低温焼結工程と、
前記焼結された合金粉末被覆層を、さらに、温度：１０５０〜１２５０℃および１０−３Ｐａ以下の真空雰囲気にて焼結して、基材の表面に、気孔率が５〜４０％の範囲である多孔質Ｃｏ基合金焼結被覆層を形成する高温焼結工程と
を有することを特徴とする多孔質Ｃｏ基合金焼結被覆材の製造方法。
Alloy powder containing Cr: 20 to 34% by mass and Mo: 1 to 10% by mass with the balance being substantially composed of Co is deposited on the surface of the substrate composed of CoCrMo alloy to cover the alloy powder. Forming a layer;
A low temperature sintering step in which the alloy powder coating layer is sintered at the same time as nitriding in a temperature range of 800 to 1000 ° C. under a nitrogen atmosphere under a load stress of 10 to 80 MPa;
The sintered alloy powder coating layer is further sintered in a vacuum atmosphere at a temperature of 1050 to 1250 ° C. and 10 −3 Pa or less, and the porosity of the base material surface is in the range of 5 to 40%. And a high-temperature sintering step of forming a porous Co-based alloy sintered coating layer, which is a method for producing a porous Co-based alloy sintered coating material.
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