Abstract
The paper shows how thermal finite-element analysis (FEA), run parallel to the experimental test phase, was used to optimize the unidirectional solidification process of Co-Cr-Mo tension compression specimens and stems of hip-joint endoprostheses by predicting optimal thermal conditions for different thermal boundary conditions and methods of process control. On the basis of the results obtained by FEA simulation of the Bridgman process, FEA is used to simulate and optimize the power-down method, a promising technique for the production of unidirectionally solidified Co-Cr-Mo hip-joint endoprostheses. Next, these results were used to simulate both unidirectional solidification methods for casting a real hip-joint endoprosthesis stem. FEA shows that it is possible to cast unidirectionally solidified stems by either processing method and that, in both cases, no microstructural defects are to be expected. Tension compression fatigue life tests of Co-Cr-Mo samples showed a fatigue life prolongation by a factor of ten for unidirectionally solidified specimens compared to conventionally cast specimens.
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