Abstract: A method for producing a zirconia-layered orthopedic implant component includes depositing zirconium onto the orthopedic implant component, thereby forming a zirconium-layered component, and converting at least a portion of the zirconium into a substantially monoclinic zirconia surface layer unaccompanied by a substantial underlying ?-phase. A method for producing a zirconia-layered orthopedic implant component includes depositing zirconium onto the orthopedic implant component by ion bombardment and deposition in a vacuum to form a zirconium-layered component including an intermix zone at least 1000 ? thick and a zirconium layer about 3-5 ?m thick, and heat treating the zirconium-layered component at a temperature of about 500-600° C. in an atmosphere containing oxygen.

Abstract: A method for attaching a porous metal layer to a dense metal substrate, wherein the method is particularly useful in forming orthopedic implants such as femoral knee components or acetabular cups. The method, in one embodiment thereof, comprises providing a structured porous layer; providing a dense metal substrate; providing a binding mixture; applying the binding mixture to the exterior of the substrate; placing the porous layer against the substrate such that the binding mixture is disposed there between forming an assembly; and heat treating the assembly to metallurgically bond the porous layer to the substrate.

Abstract: A method for attaching a porous metal layer to a dense metal substrate, wherein the method is particularly useful in forming orthopedic implants such as femoral knee components, femoral hip components, and/or acetabular cups. The method, in one embodiment thereof, comprises providing a solid metal substrate; providing a porous metal structure; contouring a surface of the porous metal structure; placing the porous structure against the substrate such that the contoured surface of the porous metal structure is disposed against the substrate, thereby forming an assembly; applying heat and pressure to the assembly in conjunction with thermal expansion of the substrate in order to metallurgically bond the porous structure and the substrate; and removing mass from the substrate after the porous structure is bonded to the substrate, thereby finish processing the assembly.