Date of this Version
The present invention provides orthopedic prosthesis having at least one metallic component that includes a metallic substrate on which an integrally formed nano-crystalline coating is formed. The coating and the substrate have at least one metallic constituent in common having an average atomic concentration in the coating that differs from an average atomic concentration in the substrate by less than about 10 percent. Further, the nano-crystalline coatings includes crystalline grains with an average size in a range of about 1 to 999 nanometers, and more preferably in a range of about 10 to 200 nanometers. A transition region that exhibits a graded reduction in average grain size separates the coating from the substrate. The coating advantageously exhibits an enhanced hardness, and a high degree of resistance to corrosion and wear. In one application, the nanocrystalline coatings of the invention are utilized to form articulating surfaces of various orthopedic devices.