Abstract: A high-purity porous metal coating is formed over a substrate by thermal spraying a metal coating material over the desired portion of the substrate in an atmospheric air environment. The metal coating material may react with the atmosphere to cause impurities in the applied coating. The impurity-rich portion of the applied coating is subsequently removed to form the high-purity porous metal coating. Process steps are included that cause the impurity-rich portion of the applied coating to be a surface portion that is removable to arrive at the high-purity coating. A protective shroud may be used to limit the amount of impurity imparted to the applied coating and/or a getter material may be employed to continually bring impurities toward the surface of the coated substrate during coating.

Abstract: A high-purity porous metal coating is formed over a substrate by thermal spraying a metal coating material over the desired portion of the substrate in an atmospheric air environment. The metal coating material may react with the atmosphere to cause impurities in the applied coating. The impurity-rich portion of the applied coating is subsequently removed to form the high-purity porous metal coating. Process steps are included that cause the impurity-rich portion of the applied coating to be a surface portion that is removable to arrive at the high-purity coating. A protective shroud may be used to limit the amount of impurity imparted to the applied coating and/or a getter material may be employed to continually bring impurities toward the surface of the coated substrate during coating.