Abstract: An apparatus and method to improve protection of a pre-coated substrate in various environments. The apparatus may include a pre-coated substrate having a substantially porous vapor-deposited coating and one or more non-porous ceramic oxide-based layers applied to the pre-coated substrate by a non-vapor deposition technique. The coefficient of thermal expansion corresponding to the non-porous ceramic oxide-based layer may substantially match the thermal expansion coefficient of the vapor-deposited coating to facilitate thermal compatibility between the two. Further, the non-porous ceramic oxide-based layer may infiltrate pores of the substantially porous vapor-deposited coating to provide a well-bonded hermetic seal that limits fluid access to the pre-coated substrate through the substantially porous vapor-deposited coating.

Abstract: A method and apparatus for adjusting the modulus of elasticity, flexural strength, or porosity of metal and ceramic implants is disclosed in one embodiment of the invention as including a green tape comprising metal or ceramic particles, or a combination thereof, for incorporation into a solid implant structure. Apertures are cut in selected regions of the green tape in order to create a desired pore structure in the solid implant structure. This pore structure may be designed to give the solid structure a desired modulus of elasticity, flexural strength, or porosity as well as to promote bone ingrowth. The green tape may then be layered in an orientation that will provide the desired pore structure and the metal or ceramic particles and layers may be fused together to create the solid implant structure.

Abstract: A method is provided for synthesizing beads using starting ceramic, metal, or mineral powders. Typical size of these round beads can range from about 0.1 mm to about 10 mm based on the processing variables. In the method, a slip is obtained which contains a metal, ceramic, and/or mineral powder dispersed in a solvent and an organic binder, such as a grain flour. Droplets of the slip are contacted with heated oil for a sufficient time to form beads. The beads are separated from the oil and dried to remove entrained water. The beads are fired at a temperature sufficient to produce beads possessing desired physical or chemical characteristics. The beads have useful biomedical applications as bone filler materials for bone fixation and bone growth. The beads may be coated with chemical catalyst agents and function as catalyst supports in chemical processes.