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1. WO2021061209 - SPHERICAL TANTALUM-TITANIUM ALLOY POWDER, PRODUCTS CONTAINING THE SAME, AND METHODS OF MAKING THE SAME

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[ EN ]

WHAT IS CLAIMED IS:

1. Tantalum-titanium alloy powder comprising

a. from 20 wt% to 80 wt% of tantalum and from 20 wt% to 80 wt% of titanium; b. a spherical shape wherein the powder has an average aspect ratio of from 1.0 to 1.25;

c. an average particle size of from about 0.5 micron to about 250 microns; d. an apparent density from about 4.5 g/cc to about 11 g/cc;

e. a true density of from 6.5 g/cc to 15.5 g/cc; and

f. a Hall flow rate of 30 sec or less.

2. The tantalum-titanium alloy powder of claim 1, wherein said alloy powder is plasma heat-treated.

3. The tantalum-titanium alloy powder of claim 1, wherein said alloy powder has an oxygen level of less than 500 ppm.

4. The tantalum-titanium alloy powder of claim 1, wherein said alloy powder has an oxygen level of from 20 ppm to 250 ppm.

5. The tantalum -titanium alloy powder of claim 1, wherein said alloy powder wherein said average aspect ratio is from 1.0 to 1.1.

6. The tantalum-titanium alloy powder of claim 1, wherein said alloy powder wherein said average aspect ratio is from 1.0 to 1.05.

7. The tantalum-titanium alloy powder of claim 1, wherein said tantalum-titanium alloy has less than 500 ppm of non-gaseous elements present.

8 The tantalum-titanium alloy powder of claim 1, wherein said average particle size is from about 0.5 micron to about 10 microns.

9. The tantalum-titanium alloy powder of claim 1, wherein said average particle size is from about 5 microns to about 25 microns.

10. The tantalum-titanium alloy powder of claim 1, wherein said average particle size is from about 15 microns to about 45 microns.

11. The tantalum-titanium alloy powder of claim 1, wherein said average particle size is from about 45 microns to about 75 microns.

12. The tantalum-titanium alloy powder of claim 1, wherein said average particle size is from about 55 microns to about 150 microns.

13. The tantalum-titanium alloy powder of claim 1, wherein said average particle size is from about 105 microns to about 250 microns.

14. The tantalum-titanium alloy powder of claim 1, wherein said alloy powder has at least one of the following properties:

a. a D10 size of from about 5 microns to 25 microns;

b. a D90 size of from about 20 microns to 80 microns; or

c. oxygen between 100 ppm to 1000 ppm.

15. An article comprising the tantalum-titanium alloy powder of claim 1.

16. The article of claim 15, wherein said article is an orthopedic implant or part thereof.

17. The article of claim 16, wherein said orthopedic implant comprises open cellular structures and solid structures.

18. The article of claim 15, wherein said article is a dental implant.

19. The article of claim 18, wherein said dental implant comprises open cellular structures and solid structures.

20. The tantalum-titanium alloy powder of claim 1, wherein said tantalum-titanium alloy further comprises, as part of the alloy, at least one additional metal element.

21. The tantalum -titanium alloy powder of claim 1, wherein said tantalum -titanium alloy is the absence of elemental nickel.

22. The tantalum-titanium alloy powder of claim 1, wherein said tantalum-titanium alloy further comprises, as part of the alloy, at least one element selected from zirconium, niobium, tungsten, molybdenum, hafnium, rhenium, or any combinations thereof.

23. A method for forming an article, said method comprising additive manufacturing said article by utilizing the alloy powder of claim 1 to form the shape of said article or part thereof.

24. The method of claim 23, wherein said additive manufacturing comprises laser powder bed fusion.

25. The method of claim 23, wherein said additive manufacturing comprises electron beam powder bed fusion.

26. The method of claim 23, wherein said additive manufacturing comprises directed energy deposition.

27. The method of claim 23, wherein said additive manufacturing comprises laser cladding via a powder or wire.

28. The method of claim 23, wherein said additive manufacturing comprises material jetting.

29. The method of claim 23, wherein said additive manufacturing comprises sheet lamination.

30. The method of claim 23, wherein said additive manufacturing comprises vat photopolymerization.

31. A method to make to the tantalum -titanium alloy powder of claim 1, said method comprising:

a. plasma heat-treating a starting alloy powder or wire to at least partially melt at least an outer surface of said starting alloy powder or wire in an inert atmosphere to obtain a heat-treated alloy powder, and

b. cooling said heat-treated alloy powder in an inert atmosphere to obtain said tantalum-titanium alloy powder.

32. The method of claim 31, wherein said starting alloy powder is an ingot-derived alloy.

33. The method of claim 31, wherein said starting alloy powder is obtained by a process comprising: i) blending a starting tantalum powder and a starting titanium powder together to form a powder blend, ii) melting said powder blend to form a liquid, iii) solidifying said liquid to an alloy ingot, iv) hydriding said alloy ingot to form a hydrided ingot, v) reducing said hydrided ingot to a hydrided alloy powder, vi) optionally screening said hydrided alloy powder to a particle size range, vii) subjecting said hydrided alloy powder to one or more dehydriding steps to form an alloy powder, viii) optionally subjecting the alloy powder to one or more deoxidation treatments, ix) optionally subjecting the alloy powder to one or more acid leaching steps.

34. The method of claim 31, wherein said starting alloy powder is obtained by a process comprising: i) condensing a starting tantalum rod or plate and a starting titanium rod or plate together to form a composite laminate, ii) melting said composite laminate to form a liquid, iii) solidifying said liquid to an alloy ingot, iv) hydriding said alloy ingot to form a hydrided ingot, v) reducing said hydrided ingot to a hydrided alloy powder, vi) optionally screening said hydrided alloy powder to a particle size range, vii) subjecting said hydrided alloy powder to one or more dehydriding steps to form an alloy powder, viii) optionally subjecting the alloy powder to one or more deoxidation treatments, ix) optionally subjecting the alloy powder to one or more acid leaching steps.

35. The method of claim 31, wherein said starting alloy powder has a first particle size distribution, and said tantalum-titanium alloy powder has a second particle size distribution, and said first particle size distribution and said second particle size distribution are within 10% of each other.

36. The method of claim 31, wherein said starting alloy powder is obtained by a process comprising: i) reacting vaporous TaC , vaporous TiCU and vaporous Na to form a Ta-Ti powder, ii) compacting the Ta-Ti powder to a compact, iii) removing excess NaCl,iv) hydriding said compact to form a hydrided compact, v) reducing said hydrided compact to a hydrided alloy powder, vi) optionally screening said hydrided alloy powder to a particle size range, vii) subjecting said hydrided alloy powder to one or more dehydriding steps to form an alloy powder, viii) optionally subjecting the alloy powder to one or more deoxidation treatments, ix) optionally subjecting the alloy powder to one or more acid leaching steps.

37. The method of claim 31, wherein said starting alloy wire is obtained by a process comprising: i) blending a starting tantalum powder and a starting titanium powder together to form a powder blend, ii) melting said powder blend to form a liquid, iii) solidifying said

liquid to an alloy ingot, iv) drawing down the alloy ingot to a wire, v) optionally subjecting the wire to one or more deoxidation treatments, vi) optionally subjecting the alloy wire to one or more acid leaching steps.