Metal alloy with rhenium effect

Abstract

A medical device is at least partially formed from a metal alloy comprising at least 15 atomic weight percent rhenium, and a medical device is partially or entirely formed from such a metal alloy.

Description

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 422,619, filed Nov. 4, 2022, which is incorporated herein by reference.

[0002] The present disclosure relates to rhenium-containing metallic alloys, and more particularly to metallic alloys having a sufficient amount of rhenium such that the ductility and tensile strength of the metallic alloy are improved, and even more particularly to metallic alloys having a sufficient amount of rhenium such that the ductility and tensile strength of the metallic alloy are improved and such rhenium-containing metallic alloys can be used to form, in whole or in part, a medical device. Background Art

[0003] Standard stainless steels, standard cobalt-chromium alloys, and standard TiAlV alloys are some of the more common metallic alloys used in medical devices. Although these alloys have successfully formed a variety of medical devices, these alloys have several drawbacks.

[0004] Many cardiovascular devices, such as stents, expandable heart valves, etc., are inserted into a patient via the patient's vascular system and then expanded at the treatment site. These devices are typically crimped onto a catheter prior to insertion into the patient. The minimum diameter to which a cardiovascular device can be crimped onto a catheter will limit the size of the cardiovascular passageway (e.g., blood vessel) into which the cardiovascular device can be inserted. A smaller crimp diameter can reduce damage to the blood vessel and / or organ (e.g., the heart, etc.) when inserting and / or placing the cardiovascular device at the treatment site. A smaller crimp diameter can also allow the cardiovascular device to be placed in blood vessels of a smaller diameter (e.g., blood vessels located in the brain, etc.).

[0005] The crimp diameter of an expandable cardiovascular device can be reduced by decreasing the thickness and / or size of the frame, struts, etc. of the cardiovascular device. However, such a reduction in size also affects the strength of the cardiovascular device after expansion. After the cardiovascular device is expanded, it must maintain its expanded shape in the treatment area; otherwise, the cardiovascular device may be displaced from the treatment area, may damage the treatment area, and / or may not function properly in the treatment area. Thus, cardiovascular devices formed of traditional materials such as standard stainless steel (e.g., 316L: 17 wt% - 19 wt% chromium, 13 wt% - 15 wt% nickel, 2 wt% - 4 wt% molybdenum, up to 2 wt% manganese, up to 0.75 wt% silicon, up to 0.03 wt% carbon, balance iron) and standard cobalt-chromium alloys (e.g., MP35N: 19 wt% - 21 wt% chromium, 34 wt% - 36 wt% nickel, 9 wt% - 11 wt% molybdenum, up to 1 wt% iron, up to 1 wt% titanium, up to 0.15 wt% manganese, up to 0.15 wt% silver, up to 0.025 wt% carbon, balance cobalt) need to maintain a frame and / or strut size / thickness that limits how small a crimp diameter can be obtained for the crimped cardiovascular device. Other types of standard cobalt-chromium alloys that have been used are standard Phynox and standard Elgiloy alloys (38 wt% - 42 wt% cobalt, 18 wt% - 22 wt% chromium, 14 wt% - 18 wt% iron, 13 wt% - 17 wt% nickel, 6 wt% - 8 wt% molybdenum) and L605 alloy (18 wt% - 22 wt% chromium, 14 wt% - 16 wt% W, 9 wt% - 11 wt% nickel, balance cobalt). Standard TiAlV alloys are also used in many medical devices (e.g., Ti-6Al-4V; 5.5 wt% - 6.5 wt% aluminum, 3.5 wt% - 4.5 wt% vanadium, balance titanium; 3.5 wt% - 4.5 wt% vanadium, 5.5 wt% - 6.75 wt% aluminum, up to 0.3 wt% iron, up to 0.2 wt% oxygen, up to 0.08 wt% carbon, up to 0.05 wt% nitrogen, up to 0.015 wt% hydrogen, up to 0.05 wt% yttrium, balance titanium).

[0006] In addition, traditional materials such as standard stainless steel (316L) and standard cobalt-chromium alloys (e.g., MP35N, etc.) have a certain degree of springback after crimping and expansion, which may prevent obtaining the minimum crimp diameter and / or may adversely affect the placement of the expandable cardiovascular device in the treatment area. During the crimping process, a crimping device is typically used to crimp the cardiovascular device onto a catheter. After the initial crimping process, traditional materials such as stainless steel and cobalt-chromium alloys spring back to a larger diameter, i.e., 9+% of the minimum crimp diameter. Therefore, the cardiovascular device must be crimped onto the catheter multiple times in an attempt to obtain a smaller crimp diameter on the catheter. However, subjecting the cardiovascular device to multiple crimpings may result in damage to the cardiovascular device (e.g., damage to the frame and / or struts of the cardiovascular device, damage to the leaflets on the expandable heart valve, etc.). Similarly, when the cardiovascular device is expanded in the treatment area, the traditional materials of the cardiovascular device will spring back 9+% of the maximum expansion diameter. Therefore, the inflatable balloon on the catheter must be pressurized multiple times to repeatedly expand the cardiovascular device in the treatment area, thereby ensuring proper expansion of the cardiovascular device. However, subjecting the cardiovascular device to multiple balloon expansions may result in damage to the cardiovascular device (e.g., damage or rupture of the frame and / or struts, etc.) and / or damage to the treatment area (e.g., blood vessel rupture, organ tissue tearing and / or perforation, etc.).

[0007] In view of the current state of the medical device field, there is a need for an improved medical device that a) exhibits less springback compared to a medical device formed from standard stainless steel, standard cobalt-chromium alloy, or standard TiAlV alloy, and b) can form a smaller crimp diameter compared to a medical device formed from standard stainless steel, standard cobalt-chromium alloy, or standard TiAlV alloy. SUMMARY OF THE INVENTION

[0008] The present disclosure relates to rhenium-containing metal alloys, specifically to metal alloys having a sufficient amount of rhenium such that the ductility and tensile strength of the metal alloy are improved, and more specifically to metal alloys having a sufficient amount of rhenium such that the ductility and tensile strength of the metal alloy are improved and such rhenium-containing metal alloys can be used to form, in whole or in part, a medical device.

[0009] In one non-limiting aspect of the present disclosure, a medical device is provided that is at least partially made of a metal alloy containing rhenium. The medical device may include an orthopedic device, a PFO (patent foramen ovale) device, a stent, a valve (e.g., a heart valve, a TAVR valve, a mitral valve replacement, a tricuspid valve replacement, a pulmonary valve replacement, etc.), a spinal implant, a frame and other structures used with a spinal implant, a vascular implant, a graft, a guidewire, a sheath, a catheter, a needle, a stent catheter, an electrophysiology catheter, a hypotube, a nail, a cutting device, an implant of any type, a pacemaker, a dental implant, a crown, a dental brace, a wire used in a medical procedure, a bone implant, an artificial intervertebral disc, an artificial spinal disc, a device for repairing, replacing and / or supporting bones (e.g., acromion, atlas, axis, calcaneus, Prosthetic implants or devices of carpal bones, clavicles, coccyx, epicondyle, medial epicondyle of humerus, femur, fibula, frontal bone, greater trochanter, humerus, ilium, ischium, mandible, maxilla, metacarpal bones, metatarsal bones, occipital bones, olecranon, parietal bones, patella, phalanges, radius, ribs, sacrum, scapula, sternum, talus, tarsal bones, temporal bones, tibia, ulna, zygomatic bones, etc.) and / or cartilage, bone plate nails, rods, screws, posts, cages, plates, pedicle screws, caps, hinges, joint systems, anchors, spacers, shafts, anchors, discs, balls, tension bands, locking connectors, other structural components used in vivo for supporting structures, mounting structures and / or repairing structures in the body (such as but not limited to human body, animal body, etc.). In a non-limiting embodiment, the medical device includes an expandable frame (e.g., stent, artificial heart valve, etc.) that can be plastically deformed radially outward by an expansion device (e.g., an inflatable balloon, etc.). In another non-limiting embodiment, the metal alloy is not a self-expanding alloy. In another non-limiting embodiment, the medical device is formed from 10%-100% (and all values ​​and ranges therebetween) of the metal alloy that contains a sufficient amount of rhenium to produce a "rhenium effect" in the metal alloy. In another non-limiting embodiment, the medical device is formed from 50%-100% of the metal alloy that contains a sufficient amount of rhenium to produce a "rhenium effect" in the metal alloy.

[0010] According to another and / or alternative aspect of the present disclosure, a metal alloy is provided that contains a sufficient amount of rhenium to produce a "rhenium effect" in the metal alloy. As defined herein, the "rhenium effect" is a) an increase in the ductility of the metal alloy by at least 10% by adding rhenium to the metal alloy, and / or b) an increase in the tensile strength of the metal alloy by at least 10% by adding rhenium to the metal alloy. It has been found that many metal alloys (e.g., standard stainless steels, standard CoCr alloys, standard TiAlV alloys, standard aluminum alloys, standard nickel alloys, standard titanium alloys, standard tungsten alloys, standard molybdenum alloys, standard copper alloys, standard MP35N alloys, standard beryllium-copper alloys, etc.) result in improved ductility and / or tensile strength. It has been found that adding rhenium to a metal alloy can result in the formation of a twinned alloy in the metal alloy, which results in an increase in the overall ductility of the metal alloy with an increase in the yield strength and tensile strength, the increase in the yield strength and tensile strength being due to the reduction and / or work hardening of the metal alloy containing the added rhenium. The rhenium effect occurs when the atomic weight of rhenium in the metal alloy is at least 15% (e.g., 15 atomic weight % - 99 atomic weight % rhenium in the metal alloy and all values and ranges therebetween). For example, for a standard stainless steel alloy, the rhenium effect can begin to exist when the stainless steel alloy is modified to include an amount of rhenium of at least 5 wt% - 10 wt% (and all values and ranges therebetween) of the stainless steel alloy. For a standard CoCr alloy, the rhenium effect can begin to exist when the CoCr alloy is modified to include an amount of rhenium of at least 4.8 wt% - 9.5 wt% (and all values and ranges therebetween) of the CoCr alloy. For a standard TiAlV alloy, the rhenium effect can begin to exist when the TiAlV alloy is modified to include an amount of rhenium of at least 4.5 wt% - 9 wt% (and all values and ranges therebetween) of the TiAlV alloy. It is understood that the rhenium content in the above examples can be greater than the minimum amount that produces the rhenium effect in the metal alloy.

[0011] According to another and / or alternative aspect of the present disclosure, the metal alloy contains at least 15 atomic weight % rhenium and at least 0.1 wt% (e.g., 0.1 wt% to 96 wt% and all values and ranges therebetween) of one or more of aluminum, bismuth, chromium, cobalt, copper, hafnium, iridium, iron, magnesium, manganese, molybdenum, nickel, niobium, osmium, rhodium, ruthenium, silicon, silver, tantalum, technetium, titanium, tungsten, vanadium, yttrium, zirconium.

[0012] According to another and / or alternative aspect of the present disclosure, the metallic alloy comprises a sufficient amount of rhenium to produce a rhenium effect in the metallic alloy, and the metallic alloy is a refractory metal alloy. As defined herein, a refractory metal alloy is a metallic alloy comprising at least 20 wt% of one or more of molybdenum, rhenium, niobium, tantalum or tungsten. Non-limiting metallic alloys include MoRe alloys, ReW alloys, MoReCr alloys, MoReTa alloys, MoReTi alloys, WCu alloys, ReCr, molybdenum alloys, rhenium alloys, tungsten alloys, tantalum alloys, niobium alloys, etc.

[0013] According to another and / or alternative aspect of the present disclosure, the metallic alloy comprises a sufficient amount of rhenium to produce a rhenium effect in the metallic alloy, and the metallic alloy is a standard stainless steel alloy that has been modified to comprise at least 15 atomic wt% rhenium. As defined herein, a standard stainless steel alloy comprises 10 wt%-28 wt% chromium, 0 wt%-35 wt% nickel, 0 wt%-4 wt% molybdenum, 0 wt%-2 wt% manganese, 0 wt%-0.75 wt% silicon, 0 wt%-0.3 wt% carbon, 0 wt%-5 wt% titanium, 0 wt%-10 wt% niobium, 0 wt%-5 wt% copper, 0 wt%-4 wt% aluminum, 0 wt%-10 wt% tantalum, 0 wt%-1 wt% Se, 0 wt%-2 wt% vanadium, 0 wt%-2 wt% tungsten and at least 50 wt% iron. The standard 316L alloy comprises 17 wt%-19 wt% chromium, 13 wt%-15 wt% nickel, 2 wt%-4 wt% molybdenum, up to 2 wt% manganese, up to 0.75 wt% silicon, up to 0.03 wt% carbon, and the balance iron.

[0014] According to another and / or alternative aspect of the present disclosure, the metallic alloy contains a sufficient amount of rhenium to produce a rhenium effect in the metallic alloy, and the metallic alloy is a standard cobalt-chromium alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, a standard CoCr alloy contains 15 wt% - 32 wt% chromium, 1 wt% - 36 wt% nickel, 2 wt% - 18 wt% molybdenum, 0 wt% - 18 wt% iron, 0 wt% - 1 wt% titanium, 0 wt% - 0.15 wt% manganese, 0 wt% - 0.15 wt% silver, 0 wt% - 0.025 wt% carbon, 0 wt% - 16 wt% tungsten, 0 wt% - 2 wt% Si, 0 wt% - 2 wt% aluminum, 0 wt% - 1 wt% iron, 30 wt% - 68 wt% cobalt. A standard MP35N alloy contains 19 wt% - 21 wt% chromium, 34 wt% - 36 wt% nickel, 9 wt% - 11 wt% molybdenum, up to 1 wt% iron, up to 1 wt% titanium, up to 0.15 wt% manganese, up to 0.15 wt% silver, up to 0.025 wt% carbon, and the balance cobalt. Standard Phynox and standard Elgiloy alloys contain 38 wt% - 42 wt% cobalt, 18 wt% - 22 wt% chromium, 14 wt% - 18 wt% iron, 13 wt% - 17 wt% nickel, 6 wt% - 8 wt% molybdenum. A standard L605 alloy contains 18 wt% - 22 wt% chromium, 14 wt% - 16 wt% tungsten, 9 wt% - 11 wt% nickel, and the balance cobalt.

[0015] According to another and / or alternative aspect of the present disclosure, the metallic alloy contains a sufficient amount of rhenium to produce a rhenium effect in the metallic alloy, and the metallic alloy is a standard TiAlV alloy that has been modified to contain at least 15 atomic weight percent rhenium. A standard TiAlV alloy contains 5.5 wt% - 6.75 wt% aluminum, 3.5 wt% - 4.5 wt% vanadium, 85 wt% - 93 wt% titanium, 0 wt% - 0.4 wt% iron, 0 wt% - 0.2 wt% carbon. A standard Ti-6Al-4V alloy contains 3.5 wt% - 4.5 wt% vanadium, 5.5 wt% - 6.75 wt% aluminum, up to 0.3 wt% iron, up to 0.2 wt% oxygen, up to 0.08 wt% carbon, up to 0.05 wt% nitrogen, up to 0.015 wt% hydrogen H, up to 0.05 wt% yttrium, and the balance titanium.

[0016] According to another and / or alternative aspect of the present disclosure, the metal alloy contains a sufficient amount of rhenium to produce a rhenium effect in the metal alloy, and the metal alloy is a standard aluminum alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, the standard aluminum alloy contains 80 wt% - 99 wt% aluminum, 0 wt% - 12 wt% silicon, 0 wt% - 5 wt% magnesium, 0 wt% - 1 wt% manganese, 0 wt% - 0.5 wt% scandium, 0 wt% - 0.5 wt% beryllium, 0 wt% - 0.5 wt% yttrium, 0 wt% - 0.5 wt% cerium, 0 wt% - 0.5 wt% chromium, 0 wt% - 3 wt% iron, 0 wt% - 0.5 wt%, 0 wt% - 9 wt% zinc, 0 wt% - 0.5 wt% titanium, 0 wt% - 3 wt% lithium, 0 wt% - 0.5 wt% silver, 0 wt% - 0.5 wt% calcium, 0 wt% - 0.5 wt% zirconium, 0 wt% - 1 wt% lead, 0 wt% - 0.5 wt% cadmium, 0 wt% - 0.05 wt% bismuth, 0 wt% - 1 wt% nickel, 0 wt% - 0.2 wt% vanadium, 0 wt% - 0.1 wt% gallium, and 0 wt% - 7 wt% copper.

[0017] According to another and / or alternative aspect of the present disclosure, the metal alloy contains a sufficient amount of rhenium to produce a rhenium effect in the metal alloy, and the metal alloy is a standard nickel alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, the standard nickel alloy contains 30 wt% - 98 wt% nickel, 5 wt% - 25 wt% chromium, 0 wt% - 65 wt% iron, 0 wt% - 30 wt% molybdenum, 0 wt% - 32 wt% copper, 0 wt% - 32 wt% cobalt, 2 wt% - 2 wt% aluminum, 0 wt% - 6 wt% tantalum, 0 wt% - 15 wt% tungsten, 0 wt% - 5 wt% titanium, 0 wt% - 6 wt% niobium, 0 wt% - 3 wt% silicon.

[0018] According to another and / or alternative aspect of the present disclosure, the metal alloy contains a sufficient amount of rhenium to produce a rhenium effect in the metal alloy, and the metal alloy is a standard titanium alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, the standard titanium alloy contains 80 wt% - 99 wt% titanium, 0 wt% - 6 wt% aluminum, 0 wt% - 3 wt% tin, 0 wt% - 1 wt% palladium, 0 wt% - 8 wt% vanadium, 0 wt% - 15 wt% molybdenum, 0 wt% - 1 wt% nickel, 0 wt% - 0.3 wt% ruthenium, 0 wt% - 6 wt% chromium, 0 wt% - 4 wt% zirconium, 0 wt% - 4 wt% niobium, 0 wt% - 1 wt% silicon, 0.0.5 wt% cobalt, 0 wt% - 2 wt% iron.

[0019] According to another and / or alternative aspect of the present disclosure, the metal alloy contains a sufficient amount of rhenium to produce a rhenium effect in the metal alloy, and the metal alloy is a standard tungsten alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, the standard tungsten alloy contains 85 wt% - 98 wt% tungsten, 0 wt% - 8 wt% nickel, 0 wt% - 5 wt% copper, 0 wt% - 5 wt% molybdenum, 0 wt% - 4 wt% iron.

[0020] According to another and / or alternative aspect of the present disclosure, the metal alloy contains a sufficient amount of rhenium to produce a rhenium effect in the metal alloy, and the metal alloy is a standard molybdenum alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, the standard molybdenum alloy contains 90 wt% - 99.5 wt% molybdenum, 0 wt% - 1 wt% nickel, 0 wt% - 1 wt% titanium, 0 wt% - 1 wt% zirconium, 0 wt% - 30 wt% tungsten, 0 wt% - 2 wt% hafnium, 0 wt% - 2 wt% lanthanum.

[0021] According to another and / or alternative aspect of the present disclosure, the metal alloy contains a sufficient amount of rhenium to produce a rhenium effect in the metal alloy, and the metal alloy is a standard copper alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, the standard copper alloy contains 55 wt% - 95 wt% copper, 0 wt% - 40 wt% zinc, 0 wt% - 10 wt% tin, 0 wt% - 10 wt% lead, 0 wt% - 1 wt% iron, 0 wt% - 5 wt% silicon, 0 wt% - 12 wt% manganese, 0 wt% - 12 wt% aluminum, 0 wt% - 3 wt% beryllium, 0 wt% - 1 wt% cobalt, 0 wt% - 20 wt% nickel.

[0022] According to another and / or alternative aspect of the present disclosure, the metal alloy contains a sufficient amount of rhenium to produce a rhenium effect in the metal alloy, and the metal alloy is a standard MP35N alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, the standard MP35N alloy contains 32 wt% - 38 wt% nickel, 18 wt% - 22 wt% chromium, 8 wt% - 12 wt% molybdenum, 0 wt% - 2 wt% iron, 0 wt% - 0.5 wt% silicon, 0 wt% - 0.5 wt% manganese, 0 wt% - 0.2 wt% carbon, 0 wt% - 2 wt% titanium, 0 wt% - 0.1 wt% phosphorus, 0 wt% - 0.1 wt% boron, 0 wt% - 0.1 wt% sulfur, and the balance cobalt.

[0023] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises a sufficient amount of rhenium to create a rhenium effect in the metal alloy, and the metal alloy is a standard beryllium-copper alloy that has been modified to include at least 15 atomic weight percent rhenium. As defined herein, the standard beryllium-copper alloy comprises 95 weight percent - 98.5 weight percent copper, 1 weight percent - 4 weight percent beryllium, 0 weight percent - 1 weight percent cobalt, and 0 weight percent - 0.5 weight percent silicon.

[0024] Several non-limiting examples of metal alloys that can be used to form, in whole or in part, the frame of a medical device are set forth below in weight percentages:

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[0070] In Examples 1 - 210, it should be understood that all of the above ranges include any value between that range and any other range between the above ranges. Any one of the above values including the ≤ symbol includes the range from 0 to the specified value and all values and ranges therebetween.

[0071] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises at least 15 atomic weight % (e.g., 10 atomic weight % - 99 atomic weight % and all values and ranges therebetween) of rhenium. In one non - limiting embodiment, the metal alloy comprises at least 15 atomic weight % (e.g., 15 atomic weight % - 99.9 atomic weight % and all values and ranges therebetween) of rhenium and 0.1 weight % - 95.5 weight % (and all values and ranges therebetween) of one or more additives selected from the group consisting of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, cerium oxide, chromium, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, lithium, magnesium, manganese, molybdenum, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and / or zirconium oxide. In another non - limiting embodiment, the metal alloy comprises at least 20 atomic weight % (e.g., 20 atomic weight % - 99.9 atomic weight % and all values and ranges therebetween) of rhenium and 0.1 weight % - 94 weight % (and all values and ranges therebetween) of one or more additives selected from the group consisting of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, cerium oxide, chromium, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, lithium, magnesium, manganese, molybdenum, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and / or zirconium oxide, and the metal alloy comprises 0 weight % - 2 weight % (and all values and ranges therebetween) of a combination of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen.

[0072] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises 35 wt% - 75 wt% (e.g., and all values and ranges therebetween) of rhenium, and 25 wt% - 65 wt% (and all values and ranges therebetween) of the metal alloy comprises two or more of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, cerium oxide, chromium, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, lithium, magnesium, manganese, molybdenum, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and / or zirconium oxide, and the metal alloy comprises 0 wt% - 2 wt% of other combinations of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen. In a non-limiting embodiment, the metal alloy comprises 50 wt% - 75 wt% rhenium, 24 wt% - 49 wt% chromium, 1 wt% - 15 wt% molybdenum, and 0 wt% - 25 wt% of one or more of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, cerium oxide, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, lithium, magnesium, manganese, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and / or zirconium oxide, and the metal alloy comprises 0 wt% - 2 wt% of a combination of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen.

[0073] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises rhenium and molybdenum, and the weight percentage of rhenium in the metal alloy is greater than the weight percentage of molybdenum in the metal alloy. In a non-limiting embodiment, the metal alloy comprises rhenium and molybdenum, and the weight percentage of rhenium in the metal alloy is greater than the weight percentage of molybdenum in the metal alloy, and the weight percentage of one or more of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium in the metal alloy is greater than the weight percentage of molybdenum in the metal alloy. In another non-limiting embodiment, the metal alloy comprises rhenium and molybdenum, and the weight percentage of rhenium in the metal alloy is greater than the weight percentage of molybdenum in the metal alloy, and the weight percentage of one or more of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium in the metal alloy is greater than the weight percentage of molybdenum in the metal alloy, and the weight percentage of molybdenum in the metal alloy is 0.1 wt% - 15 wt% (and all values and ranges therebetween). In another non-limiting embodiment, the metal alloy comprises rhenium and molybdenum, and the weight percentage of rhenium in the metal alloy is greater than the weight percentage of molybdenum in the metal alloy, and the weight percentage of one or more of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium in the metal alloy is greater than the weight percentage of molybdenum in the metal alloy, and the weight percentage of molybdenum in the metal alloy is 0.1 wt% - 15 wt%, and the metal alloy comprises 0 wt% - 2 wt% of a combination of other metals, carbon, oxygen, and nitrogen.

[0074] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises rhenium and molybdenum, and the weight percentage of rhenium in the metal alloy plus the combined weight percentage of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper and iridium is greater than the weight percentage of molybdenum. In one specific non-limiting formulation, the metal alloy comprises rhenium and molybdenum, and the weight percentage of rhenium in the metal alloy plus the combined weight percentage of bismuth, chromium, iridium, niobium, tantalum, titanium, yttrium and zirconium is greater than the weight percentage of molybdenum. In another specific non-limiting formulation, the metal alloy comprises rhenium and molybdenum, and the weight percentage of rhenium in the metal alloy plus the combined weight percentage of chromium, niobium, tantalum and zirconium is greater than the weight percentage of molybdenum. In another non-limiting specific non-limiting formulation, the weight percentage of molybdenum in the metal alloy is at least 10 wt% and less than 50 wt% (and all values and ranges therebetween) and 0 wt% - 25 wt% (and all values and ranges therebetween) of one or more of aluminum, bismuth, calcium, cerium oxide, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium and / or zirconium oxide, and the metal alloy comprises 0 wt% - 2 wt% of a combination of other metals, carbon, oxygen and nitrogen. In another non-limiting specific non-limiting formulation, the weight percentage of rhenium in the metal alloy is 41 wt% - 58.5 wt% (and all values and ranges therebetween), the weight percentage of molybdenum in the metal alloy is at least 15 wt% - 45 wt% (and all values and ranges therebetween), and the combined weight percentage of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper and iridium in the metal alloy is 11 wt% - 41 wt% (and all values and ranges therebetween). In another non-limiting specific non-limiting formulation, the weight percentage of rhenium in the metal alloy is 41 wt% - 58.5 wt% (and all values and ranges therebetween), the weight percentage of molybdenum in the metal alloy is at least 15 wt% - 45 wt% (and all values and ranges therebetween), and the combined weight percentage of bismuth, chromium, iridium, niobium, tantalum, titanium, yttrium and zirconium in the metal alloy is 11 wt% - 41 wt% (and all values and ranges therebetween). In another non-limiting specific non-limiting formulation, the weight percentage of rhenium in the metal alloy is 41 wt% - 58.5 wt% (and all values and ranges therebetween), the weight percentage of molybdenum in the metal alloy is at least 15 wt% - 45 wt% (and all values and ranges therebetween), and the combined weight percentage of chromium, niobium, tantalum and zirconium in the metal alloy is 11 wt% - 41 wt% (and all values and ranges therebetween).In another non-limiting embodiment of the present invention, the weight percentage of rhenium in the metal alloy is greater than the combined weight percentage of bismuth, chromium, iridium, niobium, tantalum, titanium, yttrium, and zirconium in the metal alloy. In another non-limiting specific non-limiting formulation, the weight percentage of rhenium in the metal alloy is greater than the combined weight percentage of chromium, niobium, tantalum, and zirconium in the metal alloy.

[0075] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises rhenium and molybdenum, and the ratio of the atomic weight percentage of rhenium to the combined atomic weight percentage of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium is from 0.7:1 to 1.5:1 (and all values and ranges therebetween), typically from 0.8:1 to 1.4:1, more typically from 0.8:1 to 1.25:1, and still more typically from about 0.9:1 to 1.1:1 (e.g., 1:1). In a specific non-limiting formulation, the metal alloy comprises rhenium and molybdenum, and the ratio of the atomic weight percentage of rhenium to the combined atomic weight percentage of bismuth, chromium, iridium, niobium, tantalum, titanium, yttrium, and zirconium is from 0.7:1 to 5.1:1 (and all values and ranges therebetween), typically from 0.8:1 to 1.5:1, more typically from 0.8:1 to 1.25:1, and still more typically from about 0.9:1 to 1.1:1 (e.g., 1:1). In another specific non-limiting formulation, the metal alloy comprises rhenium and molybdenum, and the ratio of the atomic weight percentage of rhenium to the combined atomic weight percentage of chromium, niobium, tantalum, and zirconium is from 0.7:1 to 5.1:1 (and all values and ranges therebetween), typically from 0.8:1 to 1.5:1, more typically from 0.8:1 to 1.25:1, and still more typically from about 0.9:1 to 1.1:1 (e.g., 1:1).

[0076] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises rhenium and molybdenum, and the metal alloy comprises at least 15 atomic weight % rhenium and two additional metals selected from bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium, and the atomic ratio of the two additional metals is from 0.4:1 to 2.5:1 (and all values and ranges therebetween), and typically from 0.5:1 to 2:1. In one specific non-limiting formulation, the metal alloy comprises rhenium and molybdenum, and the metal alloy comprises at least 15 atomic weight % rhenium and two of bismuth, chromium, iridium, niobium, tantalum, titanium, yttrium, and zirconium, and the atomic ratio of the two metals is from 0.4:1 to 2.5:1 (and all values and ranges therebetween), and typically from 0.5:1 to 2:1. In another specific non-limiting formulation, the metal alloy comprises rhenium and molybdenum, and the metal alloy comprises at least 15 atomic weight % rhenium and two of chromium, niobium, tantalum, and zirconium, and the atomic ratio of the two metals is from 0.4:1 to 2.5:1 (and all values and ranges therebetween), and typically from 0.5:1 to 2:1. In another non-limiting embodiment, the metal alloy comprises rhenium, molybdenum, and chromium.

[0077] According to another and / or alternative aspect of the present disclosure, the metal alloy is formed from at least 15 atomic weight % rhenium plus at least two metals selected from the group consisting of molybdenum, bismuth, chromium, iridium, niobium, tantalum, titanium, yttrium, and zirconium, and the content of other elements and compounds in the metal alloy is from 0 wt% - 0.1 wt%, typically from 0 wt% - 0.01 wt%, and more typically from 0 wt% - 0.001 wt%. In another specific non-limiting formulation, the metal alloy is formed from at least 15 atomic weight % rhenium plus at least three metals selected from the group consisting of molybdenum, chromium, niobium, tantalum, and zirconium, and the content of other elements and compounds in the metal alloy is from 0 wt% - 0.1 wt%, typically from 0 wt% - 0.01 wt%, and more typically from 0 wt% - 0.001 wt%. In another non-limiting embodiment, the metal alloy comprises rhenium, molybdenum, and chromium.

[0078] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises at least 35 wt% (e.g., 35 wt% - 75 wt% and all values and ranges therebetween) of rhenium, and the metal alloy further comprises chromium. In one non-limiting embodiment, the metal alloy comprises at least 35 wt% rhenium and at least 25 wt% (e.g., 25 wt% - 49.9 wt% and all values and ranges therebetween) of the metal alloy comprises chromium. In another non-limiting embodiment, the metal alloy comprises at least 35 wt% rhenium and at least 30 wt% of the metal alloy comprises chromium. In another non-limiting embodiment, the metal alloy comprises at least 35 wt% rhenium and at least 33 wt% of the metal alloy comprises chromium. In another non-limiting embodiment, at least 50 wt% (e.g., 50 wt% - 74.9 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium, at least 25 wt% (e.g., 25 wt% - 49.9 wt% and all values and ranges therebetween) of the metal alloy comprises chromium, and 0.1 wt% - 25 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of aluminum, bismuth, calcium, carbon, cerium oxide, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silver, tantalum, technetium, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and / or zirconium oxide. In another non-limiting embodiment, at least 50 wt% (e.g., 50 wt% - 74.9 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium, at least 25 wt% (e.g., 25 wt% - 49.9 wt% and all values and ranges therebetween) of the metal alloy comprises chromium, and 0.1 wt% - 25 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of aluminum, bismuth, calcium, carbon, cerium oxide, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silver, tantalum, technetium, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and / or zirconium oxide, and the metal alloy comprises 0 - 2 wt% of a combination of other metals, carbon, oxygen, and nitrogen. In another non-limiting embodiment, at least 55 wt% (e.g., 55 wt% - 69.9 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium, at least 30 wt% (e.g., 30 wt% - 44.9 wt% and all values and ranges therebetween) of the metal alloy comprises chromium, and 0.1 wt% - 15 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, bismuth, niobium, tantalum, titanium, vanadium, tungsten, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, yttrium, zirconium, and / or iridium, and the metal alloy comprises 0 wt% - 2 wt% of a combination of other metals, carbon, oxygen, and nitrogen.

[0079] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises 15 atomic weight percent to 60 atomic weight percent rhenium (and all values and ranges therebetween) and one or more metals selected from the group consisting of molybdenum, chromium, tantalum, niobium, titanium, and zirconium. In another non-limiting embodiment, the metal alloy comprises 15 atomic weight % to 60 atomic weight % rhenium and one or more metals selected from the group consisting of 0.5 atomic weight % to 70 atomic weight % chromium (and all values and ranges therebetween), 0.5 atomic weight % to 70 atomic weight % tantalum (and all values and ranges therebetween), 0.5 atomic weight % to 70 atomic weight % niobium (and all values and ranges therebetween), 0.5 atomic weight % to 70 atomic weight % titanium (and all values and ranges therebetween), 0.5 to 70 atomic weight % zirconium (and all values and ranges therebetween), and 0.5 atomic weight % to 70 atomic weight % molybdenum (and all values and ranges therebetween).

[0080] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises 15 atomic weight % to 50 atomic weight % rhenium (and all values and ranges therebetween) and 0.5 atomic weight % to 70 atomic weight % chromium (and all values and ranges therebetween).

[0081] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises 15 atomic weight % to 50 atomic weight % rhenium (and all values and ranges therebetween) and 0.5 atomic weight % to 70 atomic weight % tantalum (and all values and ranges therebetween).

[0082] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises 15 atomic weight % to 50 atomic weight % rhenium (and all values and ranges therebetween) and 0.5 atomic weight % to 70 atomic weight % niobium (and all values and ranges therebetween).

[0083] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises 15 atomic weight % to 50 atomic weight % rhenium (and all values and ranges therebetween) and 0.5 atomic weight % to 70 atomic weight % titanium (and all values and ranges therebetween).

[0084] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises 15 atomic weight % to 50 atomic weight % rhenium (and all values and ranges therebetween) and 0.5 atomic weight % to 70 atomic weight % zirconium (and all values and ranges therebetween).

[0085] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises 15 atomic weight % to 50 atomic weight % rhenium (and all values and ranges therebetween) and 0.5 atomic weight % to 70 atomic weight % molybdenum (and all values and ranges therebetween).

[0086] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises at least 15 atomic weight % rhenium, greater than 50 weight % titanium (e.g., 51 weight % - 80 weight % and all values and ranges therebetween), 15 weight % - 45 weight % (and all values and ranges therebetween) niobium, 1 weight % - 10 weight % (and all values and ranges therebetween) zirconium, and 1 weight % - 15 weight % (and all values and ranges therebetween) tantalum. In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight % rhenium, 58 weight % - 70 weight % titanium, 27 weight % - 37 weight % niobium, 2 weight % - 9 weight % zirconium, and 1 weight % - 15 weight % tantalum.

[0087] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises at least 15 atomic weight % rhenium, greater than 50 weight % titanium (e.g., 51 weight % - 80 weight % and all values and ranges therebetween), 15 weight % - 45 weight % (and all values and ranges therebetween) niobium, and 1 weight % - 10 weight % (and all values and ranges therebetween) molybdenum. In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight % rhenium, 58 weight % - 69 weight % titanium, 27 weight % - 33 weight % niobium, and 4 weight % - 8 weight % molybdenum.

[0088] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises at least 15 atomic weight % rhenium, 30 weight % - 60 weight % cobalt (and all values and ranges therebetween), 10 weight % - 30 weight % chromium (and all values and ranges therebetween), 5 weight % - 20 weight % iron (and all values and ranges therebetween), 5 weight % - 22 weight % nickel (and all values and ranges therebetween), and 2 weight % - 12 weight % molybdenum (and all values and ranges therebetween). In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight % rhenium, 35 weight % - 45 weight % cobalt, 15 weight % - 25 weight % chromium, 12 weight % - 20 weight % iron, 10 weight % - 20 weight % nickel, and 5 weight % - 9 weight % molybdenum.

[0089] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises at least 15 atomic weight % rhenium, 30 weight % - 60 weight % zirconium (and all values and ranges therebetween), and 30 weight % - 60 weight % molybdenum (and all values and ranges therebetween). In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight % rhenium, 35 weight % - 55 weight % cobalt, and 35 weight % - 55 weight % molybdenum.

[0090] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises at least 15 atomic weight % rhenium, 80 wt% - 95 wt% niobium (and all values and ranges therebetween), and 0.5 wt% - 10 wt% zirconium (and all values and ranges therebetween). In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight % rhenium, 85 wt% - 95 wt% niobium, and 0.75 wt% - 4 wt% niobium.

[0091] According to another and / or alternative aspect of the present disclosure, the metal alloy optionally used to partially or fully form a medical device comprises 38 wt% - 60 wt% rhenium (and all values and ranges therebetween), 29 wt% to less than 50 wt% molybdenum (and all values and ranges therebetween), and 10 wt% - 30 wt% additive metal (and all values and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 70 wt% - 90 wt% of the metal alloy (and all values and ranges therebetween); wherein the combined content of rhenium, molybdenum, and additive metal accounts for 99 wt% - 100 wt% of the metal alloy (and all values and ranges therebetween); wherein the metal additive comprises one or more metals selected from the group consisting of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium; and wherein the atomic ratio of the total content of rhenium to the additive material in the metal alloy is optionally 0.8:1 to 1.25:1 (and all values and ranges therebetween).

[0092] According to another and / or alternative aspect of the present disclosure, the metal alloy optionally used to partially or fully form a medical device comprises 38 wt% - 60 wt% rhenium (and all values and ranges therebetween), 29 wt% to less than 50 wt% molybdenum (and all values and ranges therebetween), and 10 wt% - 30 wt% additive metal (and all values and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 70 wt% - 90 wt% of the metal alloy (and all values and ranges therebetween); wherein the combined content of rhenium, molybdenum, and additive metal accounts for 99 wt% - 100 wt% of the metal alloy (and all values and ranges therebetween); wherein the metal additive comprises one or more metals selected from the group consisting of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium; and wherein the atomic ratio of the total content of rhenium to the additive material in the metal alloy is optionally 0.8:1 to 1.25:1 (and all values and ranges therebetween).

[0093] According to another and / or alternative aspect of the present disclosure, a metal alloy optionally used to partially or fully form a medical device comprises 40 wt% - 55 wt% rhenium (and all values and ranges therebetween), 30 wt% - 46 wt% molybdenum (and all values and ranges therebetween), and 12 wt% - 20 wt% additive metal (and all values and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 80 wt% - 88 wt% of the metal alloy (and all values and ranges therebetween); wherein the combined content of rhenium, molybdenum, and additive metal accounts for 99 wt% - 100 wt% of the metal alloy (and all values and ranges therebetween); wherein the metal additive comprises one or more metals selected from the group consisting of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium; and wherein the atomic ratio of rhenium to the total content of additive material in the metal alloy is optionally 0.8:1 to 1.25:1 (and all values and ranges therebetween).

[0094] According to another and / or alternative aspect of the present disclosure, a metal alloy optionally used to partially or fully form a medical device comprises 38 wt% - 60 wt% rhenium (and all values and ranges therebetween), 29 wt% to less than 50 wt% molybdenum (and all values and ranges therebetween), and 10 wt% - 30 wt% additive metal (and all values and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 70 wt% - 90 wt% of the metal alloy (and all values and ranges therebetween); wherein the combined content of rhenium, molybdenum, and additive metal accounts for 99 wt% - 100 wt% of the metal alloy (and all values and ranges therebetween); wherein the metal additive comprises chromium and optionally one or more metals selected from the group consisting of bismuth, niobium, tantalum, tungsten, titanium, vanadium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium; and wherein the atomic ratio of rhenium to the total content of additive material in the metal alloy is optionally 0.8:1 to 1.25:1 (and all values and ranges therebetween).

[0095] According to another and / or alternative aspect of the present disclosure, a metal alloy optionally used to partially or fully form a medical device comprises 40 wt% - 55 wt% rhenium (and all values and ranges therebetween), 30 wt% - 46 wt% molybdenum (and all values and ranges therebetween), and 12 wt% - 20 wt% additive metal (and all values and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 80 wt% - 88 wt% of the metal alloy (and all values and ranges therebetween); wherein the combined content of rhenium, molybdenum, and additive metal accounts for 99 wt% - 100 wt% of the metal alloy (and all values and ranges therebetween); wherein the metal additive comprises chromium and one or more metals selected from the group consisting of bismuth, niobium, tantalum, tungsten, titanium, vanadium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium; and wherein the atomic ratio of rhenium to the total content of additive material in the metal alloy is optionally 0.8:1 to 1.25:1 (and all values and ranges therebetween).

[0096] According to another and / or alternative aspect of the present disclosure, a metal alloy optionally used to partially or fully form a medical device comprises 38 wt% - 60 wt% rhenium (and all values and ranges therebetween), 29 wt% to less than 50 wt% molybdenum (and all values and ranges therebetween), and 10 wt% - 30 wt% additive metal (and all values and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 70 - 90 wt% of the metal alloy (and all values and ranges therebetween); wherein the combined content of rhenium, molybdenum, and additive metal accounts for 99 wt% - 100 wt% of the metal alloy (and all values and ranges therebetween); wherein the metal additive comprises chromium and optionally one or more metals selected from the group consisting of niobium, tantalum, and zirconium; and wherein the atomic ratio of rhenium to the total content of additive material in the metal alloy is optionally 0.8:1 to 1.25:1.

[0097] According to another and / or alternative aspect of the present disclosure, a metal alloy optionally used to partially or fully form a medical device comprises 38 wt% - 60 wt% rhenium (and all values and ranges therebetween), 29 wt% to less than 50 wt% molybdenum (and all values and ranges therebetween), and 10 wt% - 30 wt% additive metal (and all values and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 70 - 90 wt% of the metal alloy (and all values and ranges therebetween); wherein the combined content of rhenium, molybdenum, and additive metal accounts for 99 wt% - 100 wt% of the metal alloy (and all values and ranges therebetween); wherein the metal additive comprises chromium and one or more metals selected from the group consisting of bismuth, niobium, tantalum, tungsten, titanium, vanadium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and iridium; and wherein the atomic ratio of rhenium to the total content of additive material in the metal alloy is optionally 0.8:1 to 1.25:1 (and all values and ranges therebetween).

[0098] According to another and / or alternative aspect of the present disclosure, a metal alloy optionally used to partially or fully form a medical device comprises 38 wt% - 60 wt% rhenium (and all values and ranges therebetween), 29 wt% to less than 50 wt% molybdenum (and all values and ranges therebetween), and 10 wt% - 30 wt% additive metal (and all values and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 70 - 90 wt% of the metal alloy (and all values and ranges therebetween); wherein the combined content of rhenium, molybdenum, and additive metal accounts for 99 wt% - 100 wt% of the metal alloy (and all values and ranges therebetween); wherein the metal additive comprises chromium and one or more metals selected from the group consisting of niobium, tantalum, and zirconium; and wherein the atomic ratio of the total content of rhenium to the additive material in the metal alloy is optionally 0.8:1 to 1.25:1 (and all values and ranges therebetween).

[0099] According to another and / or alternative aspect of the present disclosure, at least 30 wt% (e.g., 30 wt% - 100 wt% and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic wt% rhenium. In another non-limiting embodiment, at least 40 wt% of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten. In another non-limiting embodiment, at least 50 wt% of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic wt% rhenium.

[0100] According to another and / or alternative aspect of the present disclosure, at least 50 wt% (e.g., 50 wt% - 100 wt% and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 at% rhenium, and 0 wt% - 40 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide. In another non-limiting embodiment, at least 50 wt% (e.g., 50 wt% - 99.9 wt% and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 at% rhenium, and 0.1 wt% - 40 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide. In another non-limiting embodiment, at least 50 wt% (e.g., 50 wt% - 100 wt% and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 at% rhenium, and 0 wt% - 40 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide, and the metal alloy comprises 0 wt% - 2 wt% (and all values and ranges therebetween) of a combination of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen. In another non-limiting embodiment, at least 50 wt% (e.g., 50 wt% - 99.9 wt% and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 at% rhenium, and 0.1 wt% - 40 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide, and the metal alloy comprises 0 wt% - 2 wt% (and all values and ranges therebetween) of a combination of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen.In another non-limiting embodiment, at least 55 wt% of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic wt% rhenium, and 0 wt% - 40 wt% of the metal alloy comprises one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide, and the metal alloy comprises a combination of 0 wt% - 0.1 wt% of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen. In another non-limiting embodiment, at least 55 wt% of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic wt% rhenium, and 0.1 wt% - 40 wt% of the metal alloy comprises one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide, and the metal alloy comprises a combination of 0 wt% - 0.1 wt% of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen.

[0101] According to another and / or alternative aspect of the present disclosure, the metal alloy comprises at least 30 wt% (e.g., 30 wt% - 99 wt% and all values and ranges therebetween) of rhenium and one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide. In another non-limiting embodiment, the metal alloy comprises at least 30 wt% (e.g., 30 wt% - 99 wt% and all values and ranges therebetween) of rhenium and one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide, and the metal alloy comprises 0 wt% - 2 wt% (and all values and ranges therebetween) of a combination of other metals, carbon, oxygen, and nitrogen. In another non-limiting embodiment, the metal alloy comprises at least 30 wt% (e.g., 30 - 99 wt% and all values and ranges therebetween) of rhenium and one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide, and the metal alloy comprises 0 - 0.1 wt% (and all values and ranges therebetween) of a combination of other metals, carbon, oxygen, and nitrogen. In another non-limiting embodiment, the metal alloy comprises at least 35 wt% (e.g., 35 wt% - 99 wt% and all values and ranges therebetween) of rhenium and 0.1 wt% - 65 wt% (and all values and ranges therebetween) of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide. In another non-limiting embodiment, the metal alloy comprises at least 35 wt% (e.g., 35 wt% - 99 wt% and all values and ranges therebetween) of rhenium and 0.1 wt% - 65 wt% (and all values and ranges therebetween) of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide, and the metal alloy comprises 0 wt% - 2 wt% (and all values and ranges therebetween) of a combination of other metals, carbon, oxygen, and nitrogen.In another non-limiting embodiment, the metal alloy comprises at least 35 wt% (e.g., 35 - 99.9 wt% and all values and ranges therebetween) of rhenium and 0.1 - 65 wt% (and all values and ranges therebetween) of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide, and the metal alloy comprises 0 - 0.1 wt% (and all values and ranges therebetween) of a combination of other metals, carbon, oxygen, and nitrogen. In another non-limiting embodiment, the metal alloy comprises at least 40 wt% (e.g., 40 - 99.9 wt% and all values and ranges therebetween) of rhenium and 0.1 - 60 wt% (and all values and ranges therebetween) of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide. In another non-limiting embodiment, the metal alloy comprises at least 40 wt% (e.g., 40 - 99.9 wt% and all values and ranges therebetween) of rhenium and 0.1 - 60 wt% (and all values and ranges therebetween) of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide, and the metal alloy comprises 0 - 2 wt% (and all values and ranges therebetween) of a combination of other metals, carbon, oxygen, and nitrogen. In another non-limiting embodiment, the metal alloy comprises at least 40 wt% (e.g., 40 - 99.9 wt% and all values and ranges therebetween) of rhenium and 0.1 - 60 wt% (and all values and ranges therebetween) of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide, and the metal alloy comprises 0 - 0.1 wt% (and all values and ranges therebetween) of a combination of other metals, carbon, oxygen, and nitrogen.

[0102] According to another and / or alternative aspect of the present disclosure, a metal alloy is provided, wherein at least 20 wt% (e.g., 20 wt% - 99 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium. In a non-limiting embodiment, the metal alloy comprises at least 20 wt% (e.g., 20 wt% - 99.9 wt% and all values and ranges therebetween) rhenium and 0.1 wt% - 80 wt% of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, zirconium oxide and / or alloys of one or more of such components. In another non-limiting embodiment, the metal alloy comprises at least 20 wt% (e.g., 30 wt% - 99.9 wt% and all values and ranges therebetween) rhenium and 0.1 wt% - 80 wt% of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, zirconium oxide and / or alloys of one or more of such components. In another non-limiting embodiment, the metal alloy comprises at least 30 wt% (e.g., 30 - 99.9 wt% and all values and ranges therebetween) rhenium and 0.1 - 70 wt% of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, zirconium oxide and / or alloys of one or more of such components. In another non-limiting embodiment, the metal alloy comprises at least 30 wt% (e.g., 30 wt% - 99.9 wt% and all values and ranges therebetween) rhenium and 0.1 wt% - 70 wt% (and all values and ranges therebetween) of one or more of copper, chromium, hafnium, iridium, manganese, molybdenum, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, zirconium and / or alloys of one or more of such components. In another non-limiting embodiment, the metal alloy comprises at least 35 wt% (e.g., 35 - 99.9 wt% and all values and ranges therebetween) rhenium and 0.1 - 65 wt% of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, zirconium oxide and / or alloys of one or more of such components.In another non-limiting embodiment, the metal alloy comprises at least 35 wt% (e.g., 35 wt% - 99.9 wt% and all values and ranges therebetween) of rhenium and from 0.1 wt% to 65 wt% (and all values and ranges therebetween) of one or more of copper, chromium, hafnium, iridium, manganese, molybdenum, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, zirconium, and / or one or more of alloys of one or more of such components. In another non-limiting embodiment, in another non-limiting embodiment, the metal alloy comprises from 35 wt% to 60 wt% (and all values and ranges therebetween) of rhenium and from 40 wt% to 65 wt% of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, zirconium oxide, and / or one or more of alloys of one or more of such components. In another non-limiting embodiment, the metal alloy comprises from 35 wt% to 60 wt% (and all values and ranges therebetween) of rhenium and from 40 wt% to 65 wt% (and all values and ranges therebetween) of one or more of copper, chromium, hafnium, iridium, manganese, molybdenum, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, zirconium, and / or one or more of alloys of one or more of such components. In another non-limiting embodiment, the metal alloy comprises at least 40 wt% (e.g., 40 - 99.9 wt% and all values and ranges therebetween) of rhenium and from 0.1 to 60 wt% of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, zirconium oxide, and / or one or more of alloys of one or more of such components. In another non-limiting embodiment, the metal alloy comprises at least 40 wt% (e.g., 40 - 99.9 wt% and all values and ranges therebetween) of rhenium and from 0.1 to 60 wt% (and all values and ranges therebetween) of one or more of copper, chromium, hafnium, iridium, manganese, molybdenum, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, zirconium, and / or one or more of alloys of one or more of such components. In one non-limiting embodiment, the metal alloy comprises at least 50 wt% (e.g., 50 wt% - 99.9 wt% and all values and ranges therebetween) of rhenium and from 0.1 wt% to 50 wt% of one or more of aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, zirconium oxide, and / or one or more of alloys of one or more of such components.In another non-limiting embodiment, the metal alloy comprises at least 50 wt% (e.g., 50 wt% - 99.9 wt% and all values and ranges therebetween) rhenium and 0.1 wt% - 50 wt% (and all values and ranges therebetween) of one or more of copper, chromium, hafnium, iridium, manganese, molybdenum, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, zirconium, and / or one or more of alloys of such components.

[0103] According to another and / or alternative aspect of the present disclosure, the metal for forming the metal alloy comprises at least 15 atomic weight percent rhenium and tungsten and optionally one or more alloying agents such as, but not limited to, aluminum, bismuth, calcium, carbon, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, vanadium, yttrium, yttrium oxide, zinc, zirconium, and zirconium oxide (e.g., WRe, WReMo, etc.) of one or more of such components. Although the metal alloy is described as comprising one or more metals and / or metal oxides, it is understood that some of the metals and / or metal oxides in the metal alloy may replace one or more materials selected from the group consisting of ceramics, plastics, thermoplastics, thermosetting materials, rubbers, laminates, nonwoven materials, and the like. In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight percent rhenium and up to 40 weight percent rhenium and at least 60 weight percent tungsten. In a non-limiting embodiment, the total weight percentage of tungsten and rhenium in the tungsten-rhenium alloy is at least about 95 weight percent, typically at least about 99 weight percent, more typically at least about 99.5 weight percent, still more typically at least about 99.9 weight percent, and yet more typically at least about 99.99 weight percent. In another non-limiting formulation, the metal alloy comprises at least 15 atomic weight percent rhenium and up to 47.5 weight percent rhenium and at least 20 weight percent - 80 weight percent tungsten (and all values and ranges therebetween) and 1 weight percent - 47.5 weight percent molybdenum (and all values and ranges therebetween). The total weight percentage of tungsten, rhenium, and molybdenum in the tungsten-rhenium-molybdenum alloy is at least about 95 weight percent, typically at least about 99 weight percent, more typically at least about 99.5 weight percent, still more typically at least about 99.9 weight percent, and yet more typically at least about 99.99 weight percent. In one non-limiting specific tungsten-rhenium-molybdenum alloy, the weight percentage of tungsten is greater than the weight percentage of rhenium and also greater than the weight percentage of molybdenum. In another non-limiting specific tungsten-rhenium-molybdenum alloy, the weight percentage of tungsten is greater than 50 weight percent of the tungsten-rhenium-molybdenum alloy. In another non-limiting specific tungsten-rhenium-molybdenum alloy, the weight percentage of tungsten is greater than the weight percentage of rhenium but less than the weight percentage of molybdenum. In another non-limiting specific tungsten-rhenium-molybdenum alloy, the weight percentage of tungsten is greater than the weight percentage of molybdenum but less than the weight percentage of rhenium. In another non-limiting specific tungsten-rhenium-molybdenum alloy, the weight percentage of tungsten is less than the weight percentage of rhenium and also less than the weight percentage of molybdenum.

[0104] According to another and / or alternative aspect of the present disclosure, a metal alloy is provided, wherein at least 30 wt% (e.g., 30 wt% - 99 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium. In another non-limiting embodiment, at least 35 wt% of the metal alloy comprises rhenium. In another non-limiting embodiment, at least 35 wt% (e.g., 35 wt% - 99.9 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium, and 0.1 wt% - 65 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, niobium, tantalum, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and / or iridium. In another non-limiting embodiment, 35 wt% - 60 wt% (and all values and ranges therebetween) of the metal alloy comprises rhenium, and 40 wt% - 65 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and / or iridium. In another non-limiting embodiment, 35 wt% - 60 wt% (e.g., and all values and ranges therebetween) of the metal alloy comprises rhenium, and 40 wt% - 65 wt% (and all values and ranges therebetween) of the metal alloy comprises two or more of molybdenum, niobium, tantalum, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and / or iridium. In another non-limiting embodiment, 35 wt% - 60 wt% (e.g., and all values and ranges therebetween) of the metal alloy comprises rhenium, and 40 wt% - 65 wt% (and all values and ranges therebetween) of the metal alloy comprises three or more of molybdenum, niobium, tantalum, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and / or iridium.

[0105] According to another and / or alternative aspect of the present disclosure, the metal used to form the metal alloy comprises at least 35 wt% rhenium (e.g., 35 wt% - 99.9 wt% and all values and ranges therebetween) and one or more alloying agents such as, but not limited to, molybdenum, niobium, tantalum, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and / or iridium, and / or an alloy of one or more of such components. In a non-limiting formulation, the metal alloy comprises 40 wt% - 99.9 wt% rhenium and one or more of molybdenum, niobium, tantalum, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and / or iridium. In a non-limiting formulation, the metal alloy comprises rhenium and one or more of molybdenum, niobium, tantalum, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and / or iridium.

[0106] According to another and / or alternative aspect of the present disclosure, the metal for forming a metal alloy comprises at least 15 atomic weight % of rhenium, molybdenum, and one or more alloying metals selected from the group consisting of bismuth, chromium, copper, hafnium, iridium, manganese, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, yttrium, and zirconium. In one non-limiting embodiment, the combined weight percentage of rhenium and alloying metals in the metal alloy is greater than or equal to the weight percentage of molybdenum in the metal alloy. In another non-limiting embodiment, the combined weight percentage of rhenium and alloying metals in the metal alloy is greater than the weight percentage of molybdenum in the metal alloy. In another non-limiting embodiment, the weight percentage of molybdenum in the metal alloy is at least 10 wt% and less than 60 wt% (and all values and ranges therebetween). In another non-limiting embodiment, the weight percentage of rhenium in the metal alloy is 35 wt% - 60 wt% (and all values and ranges therebetween). In another non-limiting embodiment, the combined weight percentage of alloying metals is 5 wt% - 45 wt% of the metal alloy (and all values and ranges therebetween). In another non-limiting embodiment, the weight percentage of rhenium in the metal alloy is greater than the combined weight percentage of alloying metals. In another non-limiting embodiment, the combined weight percentage of rhenium, molybdenum, and one or more alloying metals in the metal alloy is at least 99.9 wt%. In another non-limiting embodiment, the alloying metal comprises chromium. In another non-limiting embodiment, the alloying metal comprises chromium and one or more metals selected from the group consisting of bismuth, zirconium, iridium, niobium, tantalum, titanium, and yttrium. In another non-limiting embodiment, the alloying metal comprises chromium and one or more metals selected from the group consisting of bismuth, zirconium, iridium, niobium, tantalum, titanium, and yttrium; and wherein the atomic ratio of chromium to each or all of the metals selected from the group consisting of bismuth, chromium, iridium, niobium, tantalum, titanium, and yttrium is from 0.4:1 to 2.5:1 (and all values and ranges therebetween). In another non-limiting embodiment, the alloying metal comprises chromium and one or more metals selected from the group consisting of zirconium, niobium, and tantalum. In another non-limiting embodiment, the alloying metal comprises a first metal selected from the group consisting of bismuth, chromium, iridium, niobium, tantalum, titanium, yttrium, and zirconium, and a second metal selected from the group consisting of bismuth, chromium, iridium, niobium, tantalum, titanium, yttrium, and zirconium; and wherein the first metal and the second metal are different; and wherein the atomic ratio of the first metal to the second metal is from 0.4:1 to 2.5:1 (and all values and ranges therebetween). In another non-limiting embodiment, the alloying metal comprises a first metal selected from the group consisting of chromium, niobium, tantalum, and zirconium, and a second metal selected from the group consisting of chromium, niobium, tantalum, and zirconium; and wherein the first metal and the second metal are different; and wherein the atomic ratio of the first metal to the second metal is from 0.4:1 to 2.5:1 (and all values and ranges therebetween).

[0107] According to another and / or alternative aspect of the present disclosure, at least 35 wt% (e.g., 35 wt% - 75 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium, and the metal alloy further comprises chromium. In one non-limiting embodiment, at least 25 wt% (e.g., 25 wt% - 49.9 wt% and all values and ranges therebetween) of the metal alloy comprises chromium. In another non-limiting embodiment, at least 30 wt% of the metal alloy comprises chromium. In another non-limiting embodiment, at least 33 wt% of the metal alloy comprises chromium. In another non-limiting embodiment, at least 50 wt% (e.g., 50 wt% - 74.9 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium, at least 25 wt% (e.g., 25 wt% - 49.9 wt% and all values and ranges therebetween) of the metal alloy comprises chromium, and 0.1 wt% - 25 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, bismuth, niobium, tantalum, titanium, vanadium, tungsten, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, yttrium, zirconium, and / or iridium. In another non-limiting embodiment, at least 55 wt% (e.g., 55 wt% - 69.9 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium, at least 30 wt% (e.g., 30 wt% - 44.9 wt% and all values and ranges therebetween) of the metal alloy comprises chromium, and 0.1 wt% - 15 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, bismuth, niobium, tantalum, titanium, vanadium, tungsten, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, yttrium, zirconium, and / or iridium. In another non-limiting embodiment, at least 60 wt% (e.g., 60 wt% - 69.9 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium, at least 30 wt% (e.g., 30 wt% - 39.9 wt% and all values and ranges therebetween) of the metal alloy comprises chromium, and 0.1 wt% - 10 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, bismuth, niobium, tantalum, titanium, vanadium, tungsten, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, yttrium, zirconium, and / or iridium. In another non-limiting embodiment, at least 62 wt% (e.g., 62 wt% - 67.9 wt% and all values and ranges therebetween) of the metal alloy comprises rhenium, at least 32 wt% (e.g., 32 wt% - 32.9 wt% and all values and ranges therebetween) of the metal alloy comprises chromium, and 0.1 wt% - 6 wt% (and all values and ranges therebetween) of the metal alloy comprises one or more of molybdenum, bismuth, niobium, tantalum, titanium, vanadium, tungsten, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, yttrium, zirconium, and / or iridium.

[0108] According to another and / or alternative aspect of the present disclosure, the metal alloy optionally comprises less than about 5 wt% (e.g., 0 wt% - 4.999999 wt% and all values and ranges therebetween) of other metals and / or impurities, typically 0 wt% - 1 wt%, more typically 0 wt% - 0.1 wt%, even more typically 0 wt% - 0.01 wt%, and still even more typically 0 - 0.001 wt%. The high purity level of the metal alloy results in the formation of a more uniform alloy, which in turn results in a more uniform density throughout the metal alloy and also results in the desired yield strength and ultimate tensile strength of the metal alloy. In one specific non-limiting formulation, the metal alloy is formed from rhenium plus at least one additive selected from the group consisting of aluminum, bismuth, calcium, cerium oxide, chromium, cobalt, copper, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rare earth metals, rhodium, ruthenium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, yttrium oxide, zinc, zirconium, and / or zirconium oxide, and the content of the metal alloy containing other elements and compounds is 0 wt% - 0.1 wt%, typically 0 wt% - 0.01 wt%, and more typically 0 wt% - 0.001 wt%.

[0109] According to another and / or alternative aspect of the present disclosure, there is provided a medical device (e.g., a stent, an artificial heart valve, etc.) that is at least partially formed of a metal alloy and is configured to be radially contractible to a contracted or crimped state for introduction into the body on a delivery catheter and radially expandable to an expanded state for implanting the artificial heart valve at a desired location in the body (e.g., blood vessels, heart, ureter, bile duct, pancreatic duct, esophagus, lung, eye, sinus, oral stent, etc.). The frame of the medical device can be formed of a plastically expandable material that allows the frame to be crimped into a smaller profile for delivery and expansion of the medical device using an expansion device (such as the balloon of a balloon catheter).

[0110] According to another and / or alternative aspect of the present disclosure, there is provided a medical device that includes a frame optionally coated with a polymeric material (e.g., silicone, PTFE, ePTFE, polyurethane, polyolefin, hydrogel, biomaterial (e.g., pericardium or biopolymer such as collagen, gelatin, or hyaluronic acid derivative), etc.). The coating can be used to partially or fully encapsulate the struts on the frame and / or fill the openings between the struts.

[0111] According to another and / or alternative aspect of the present disclosure, a metal alloy for forming at least a portion of a medical device has one or more improved properties (e.g., strength, durability, hardness, biostability, bendability, coefficient of friction, radial strength, flexibility, tensile strength, tensile elongation, longitudinal elongation, stress-strain properties, reduced springback, radiopacity, thermosensitivity, biocompatibility, improved fatigue life, crack resistance, crack growth resistance, reduced magnetic susceptibility, etc.), improved consistency during bending, reduced springback, increased yield strength, improved fatigue ductility, improved durability, improved fatigue life, reduced adverse tissue reaction, reduced metal ion release, reduced corrosion, reduced allergic reaction, improved hydrophilicity, reduced toxicity, reduced metal component thickness, improved bone ingrowth and / or reduced ion release in tissue. These one or more improved physical properties of the metal alloy can be achieved in a medical device without increasing the volume, capacity, and / or weight of the medical device, and in some cases, these improved physical properties can be obtained even when the volume, capacity, and / or weight of the medical device is reduced compared to a medical device formed at least in part from standard stainless steel, standard titanium alloy, or standard cobalt and chromium alloy materials.

[0112] Thus, the metal alloy used to at least partially form a medical device can: 1) increase the radiopacity of the medical device; 2) increase the radial strength of the medical device; 3) increase the yield strength and / or ultimate tensile strength of the medical device; 4) improve the stress-strain characteristics of the medical device; 5) improve the crimping and / or dilation characteristics of the medical device; 6) improve the bendability and / or flexibility of the medical device; 7) improve the strength and / or durability of the medical device; 8) improve the hardness of the medical device; 9) improve the resilience characteristics of the medical device; 10) improve the bio-stability and / or biocompatibility characteristics of the medical device; 11) increase the fatigue resistance of the medical device; 12) resist cracks in the medical device and resist crack propagation; 13) enable the manufacture of smaller, thinner, and / or lighter medical devices; 14) reduce the outer diameter of the crimped medical device; 15) improve the conformity of the medical device to the shape of the treatment area when the medical device is used and / or dilated in the treatment area; 16) reduce the amount of spring-back of the medical device to the shape of the treatment area when the medical device is dilated in the treatment area; 17) increase the yield strength of the medical device; 18) improve the fatigue ductility of the medical device; 18) improve the durability of the medical device; 19) improve the fatigue life of the medical device; 20) reduce the adverse tissue reaction after implantation of the medical device; 21) reduce the metal ion release after implantation of the medical device; 22) reduce the corrosion of the medical device after implantation of the medical device; 23) reduce the allergic reaction after implantation of the medical device; 24) improve the hydrophilicity of the medical device; 25) reduce the thickness of the metal components of the medical device; 26) improve the bone fusion with the medical device; 27) reduce the ion release from the medical device into the tissue; 28) reduce the magnetic susceptibility when the medical device is implanted into a patient, and / or 29) reduce the toxicity of the medical device after implantation.

[0113] The medical device is optionally subjected to one or more manufacturing processes. These manufacturing processes can include, but are not limited to, dilation, laser cutting, etching, crimping, annealing, drawing, pilgering, electroplating, electropolishing, machining, plasma coating, 3D printing coating, chemical vapor deposition, chemical polishing, cleaning, pickling, ion beam deposition or implantation, sputter coating, vacuum deposition, etc.

[0114] According to another and / or alternative aspect of the present disclosure, the metallic alloy optionally contains a certain amount of carbon and oxygen; however, this is not necessary. It has been found that these two elements affect the forming characteristics and brittleness of the metallic alloy. The controlled atomic ratio of carbon and oxygen in the metallic alloy also minimizes the tendency of the metallic alloy to form microcracks during at least partially forming the metallic alloy into a medical device and / or during the use and / or expansion of the medical device in the body. Controlling the atomic ratio of carbon to oxygen in the metallic alloy allows for the redistribution of oxygen in the metallic alloy to minimize the tendency of microcracks in the metallic alloy during at least partially forming the metallic alloy into a medical device and / or during the use and / or expansion of the medical device in the body. It is believed that the atomic ratio of carbon to oxygen in the metallic alloy helps to minimize the tendency of microcracks in the metallic alloy and increase the elongation of the metallic alloy, both of which can affect one or more physical properties of the metallic alloy that are useful or desirable when forming and / or using the medical device. The atomic ratio of carbon to oxygen can be as low as about 0.2:1 (e.g., 0.2:1 to 50:1 and all values and ranges therebetween). In a non-limiting formulation, the atomic ratio of carbon to oxygen in the metallic alloy is typically at least about 0.3:1. Generally, the carbon content of the metallic alloy is less than about 0.1 wt% (e.g., 0 wt% - 0.0999999 wt% and all values and ranges therebetween), and more typically 0 wt% - 0.01 wt%. Too high a carbon content may have an adverse effect on the physical properties of the metallic alloy. Generally, the oxygen content is to be kept at a very low level. In a non-limiting formulation, the oxygen content is less than about 0.1 wt% of the metallic alloy (e.g., 0 wt% - 0.0999999 wt% and all values and ranges therebetween), and typically 0 wt% - 0.01 wt%. It is believed that when the oxygen content in the metallic alloy exceeds a certain amount, by tightly controlling the ratio of carbon to oxygen, the tendency of the metallic alloy to form microcracks during the formation of the medical device and after the medical device is inserted into the patient's body is very low. In a non-limiting arrangement, when the oxygen content in the metallic alloy of the metallic alloy is greater than about 100 ppm, the atomic ratio of carbon to oxygen in the metallic alloy is at least about 2.5:1.

[0115] According to another and / or alternative aspect of the present disclosure, the metallic alloy optionally includes a controlled amount of nitrogen; however, this is not necessary. A large amount of nitrogen in the metallic alloy may have an adverse effect on the ductility of the metallic alloy. This, in turn, may have an adverse effect on the elongation characteristics of the metallic alloy. An excessive nitrogen content in the metallic alloy may begin to cause an unacceptably low ductility of the metallic alloy, thereby adversely affecting one or more physical properties of the metallic alloy that are useful or desirable when forming and / or using a medical device. In one non-limiting formulation, the metallic alloy includes less than about 0.001 wt% nitrogen (e.g., 0 wt% to 0.0009999 wt% and all values and ranges therebetween). It is believed that the nitrogen content in the metallic alloy should be lower than the carbon or oxygen content. In one non-limiting formulation, the atomic ratio of carbon to nitrogen is at least about 1.5:1 (e.g., 1.5:1 to 400:1 and all values and ranges therebetween). In another non-limiting formulation, the atomic ratio of oxygen to nitrogen is at least about 1.2:1 (e.g., 1.2:1 to 150:1 and all values and ranges therebetween).

[0116] According to another and / or alternative aspect of the present disclosure, a medical device is generally designed to include at least about 5 wt% of the metallic alloy (e.g., 5 wt% - 100 wt% and all values and ranges therebetween). In one non-limiting embodiment of the present disclosure, the medical device includes at least about 50 wt% of the metallic alloy. In another non-limiting embodiment of the present disclosure, the medical device includes at least about 95 wt% of the metallic alloy. In one specific configuration, when the medical device includes an expandable frame, the expandable frame is formed of 50 wt% - 100 wt% (and all values and ranges therebetween) of the metallic alloy, and typically 75 wt% - 100 wt% of the metallic alloy.

[0117] In yet another and / or alternative non-limiting aspect of the present invention, the novel metallic alloy for forming all or a part of a medical device 1) is not clad, metal sprayed, electroplated, and / or formed (e.g., cold worked, hot worked, etc.) onto another metal, or 2) does not have another metal or metallic alloy metal sprayed, electroplated, clad, and / or formed onto the novel metallic alloy. It should be understood that in some applications, when forming all or a part of a medical device, the novel metallic alloy of the present invention may be clad, metal sprayed, electroplated, and / or formed onto another metal, or another metal or metallic alloy may be electroplated, metal sprayed, clad, and / or formed onto the novel metallic alloy.

[0118] In yet another and / or alternative non-limiting aspect of the present invention, the novel alloy can be used to form a) a coating on a portion of all medical devices, or b) the core of a portion or all of a medical device. In one non-limiting embodiment, the novel alloy can be used as a coating on the articulating points of an artificial joint. Such a coating can provide better wear resistance, scratch resistance, and / or the beneficial effect of eliminating the leaching of harmful metal ions (i.e., Co, Cr, etc.) from the joint surface when the joint surface is subjected to fretting wear (i.e., scratching during relative movement). It is understood that the novel alloy can have other or additional advantages. It is also understood that the novel alloy can be coated on other or additional types of medical devices (e.g., spinal rods, stents, etc.). The composition of the novel alloy coating is different from the composition of the material surface on which the novel alloy is coated. The coating thickness of the novel alloy is non-limiting (e.g., 1 μm to 1 inch and all values and ranges therebetween). In one non-limiting example, a medical device in the form of a coated rod is provided, wherein the core of the rod is formed of a metal or a novel alloy (e.g., chromium alloy, titanium, titanium alloy, stainless steel, ferroalloy, CoCr alloy, rhenium alloy, molybdenum alloy, tungsten alloy, Ta-W alloy, refractory metal alloy, MoTa alloy, MoRe alloy, etc.) or a ceramic or composite material, and another layer of the coated rod is formed of the novel alloy. The core of the rod and the other layer can each form 10%-99% (and all values and ranges therebetween) of the total cross-section of the rod. The novel alloy coating can be used to form a hard surface at specific locations as well as over the entire surface of the medical device. The base hardness of the novel alloy can be as low as 300 Vickers hardness and / or as high as 500 Vickers hardness (and all values and ranges therebetween). In cases where the properties of a fully annealed material are required but only the surface needs to be hardened, the present disclosure includes a method that can provide the beneficial effect of a softer metal alloy having a harder outer surface or shell. One non-limiting example is an orthopedic screw, where a softer ferroalloy is required to obtain high ductility and ease of machining. At the same time, the finished screw requires a hard shell. When the novel alloy is used, the internal hardness can be in the range of 250 Vickers hardness to 550 Vickers hardness (and all values and ranges therebetween), while the external hardness can vary between 350 Vickers hardness and 1000 Vickers hardness (and all values and ranges therebetween). It is understood that other internal and external hardness values can be used for medical devices.

[0119] In another non-limiting embodiment, the medical device may be in the form of a rod. The core of the rod may be formed from a novel alloy, and then the exterior of the core may be coated with one or more other materials (e.g., another type of metal or novel alloy [such as, for example, chromium alloy, titanium, titanium alloy, stainless steel, ferroalloy, CoCr alloy, rhenium alloy, molybdenum alloy, tungsten alloy, Ta-W alloy, refractory metal alloy, MoTa alloy, MoRe alloy, etc.], polymer coating, ceramic coating, composite material coating, etc.). Such a rod may be used, for example, in orthopedic applications such as, but not limited to, spinal rods and / or pedicle screw systems. Non-limiting beneficial effects of using a novel alloy in the core of the medical device may include reducing the size of the medical device, increasing the strength of the medical device, and / or maintaining or reducing the cost of the medical device. It will be understood that the novel alloy may have other or additional advantages. It will also be understood that the novel alloy may form the core of other or additional types of medical devices. The core size and / or thickness of the novel alloy is non-limiting. In one non-limiting example, a medical device in the form of a cladded rod is provided, wherein the core of the rod is formed from a novel alloy and another layer of the cladded rod is formed from a different metal component (e.g., chromium alloy, titanium, titanium alloy, stainless steel, ferroalloy, CoCr alloy, rhenium alloy, molybdenum alloy, tungsten alloy, Ta-W alloy, refractory metal alloy, MoTa alloy, MoRe alloy, etc.). The core of the rod and the other layer may each form 10%-99% (and all values and ranges therebetween) of the total cross-section of the rod. It will also be understood that the novel alloy may form the core of other or additional types of medical devices.

[0120] According to another and / or alternative aspect of the present disclosure, the medical device may optionally be formed from a tube or rod of a refractory metal or formed into a shape that is at least 80% of the final net shape of the medical device.

[0121] According to another and / or alternative aspect of the present disclosure, when the medical device is at least partially formed of the metal alloy of the present disclosure, the metal alloy has several physical properties that positively affect the medical device. In one non-limiting embodiment of the present disclosure, the average Vickers hardness of the metal alloy of the present disclosure used to at least partially form the medical device is optionally at least about 150 Vickers hardness (e.g., 150 Vickers hardness - 300 Vickers hardness and all values and ranges therebetween), and typically 160 Vickers hardness - 240 Vickers hardness; however, this is not required. The metal alloy of the present disclosure generally has an average hardness greater than that of standard stainless steel. In another and / or alternative non-limiting embodiment of the present disclosure, the average ultimate tensile strength of the metal alloy of the present disclosure is optionally at least about 125 ksi (e.g., 125 ksi - 300 ksi and all values and ranges therebetween); however, this is not required. In another and / or alternative non-limiting embodiment of the present disclosure, the average yield strength of the metal alloy of the present disclosure is optionally at least about 100 ksi (e.g., 100 ksi - 275 ksi and all values and ranges therebetween); however, this is not required. In another and / or alternative non-limiting embodiment of the present disclosure, the average grain size of the metal alloy of the present disclosure used to at least partially form the medical device is optionally no greater than about 4 ASTM (e.g., 4 ASTM to 20 ASTM using ASTM E112 and all values and ranges therebetween, e.g., 0.35 microns to 90 microns, and all values and ranges therebetween). The small grain size of the metal alloy of the present disclosure enables the medical device to have a desired elongation and ductility, which can be used to enable the medical device to be formed, crimped, and / or expanded.

[0122] In another and / or alternative non-limiting embodiment of the present disclosure, the average tensile elongation of the metallic alloy of the present disclosure used to at least partially form a medical device is optionally at least about 25% (e.g., 25%-50% average tensile elongation and all values and ranges therebetween). An average tensile elongation of at least 25% of the metallic alloy facilitates proper expansion of the medical device when positioned in a treatment area of the body. A medical device that does not have an average tensile elongation of at least about 25% may be more prone to forming microcracks and / or fractures during the formation, crimping, and / or expansion of the medical device. The unique combination of metals in the metallic alloy of the present disclosure, combined with achieving the desired alloy purity and composition and the desired grain size of the metallic alloy, results in 1) a medical device having the desired high ductility at about room temperature, 2) a medical device having the desired tensile elongation, 3) a homogeneous or solid solution of the metallic alloy having high radiopacity, 4) reducing or preventing the formation of microcracks and / or fractures in the metallic alloy of the tube of the present disclosure when the tube is sized and / or cut to form a medical device, 5) reducing or preventing the formation of microcracks and / or fractures in the medical device when the device is crimped, 6) reducing or preventing the formation of microcracks and / or fractures in the medical device when the medical device is bent and / or expanded in the body, 7) a medical device having the desired ultimate tensile strength and yield strength, 8) a medical device having a very thin wall thickness and still having the desired radial force required to hold the medical device in an open state when expanded, 9) a medical device that exhibits less rebound when the medical device is crimped onto a delivery system and / or expanded in the body, 10) a medical device that exhibits improved conformance to the shape of the treatment area in the body when the medical device is expanded in the body, 11) a medical device that exhibits improved fatigue ductility, and / or 12) a medical device that exhibits improved durability.

[0123] According to another and / or alternative aspect of the present disclosure, the metal alloy is optionally formed at least in part by a forging process; however, this is not necessary. In a non-limiting embodiment, the metal alloy is forged to at least partially or fully achieve the final dimensions of one or more parts of the medical device. The forging die can be shaped to fit the final dimensions of the medical device; however, this is not necessary. In the case where there is an undercut in the hollow structure of the medical device (which is not necessary), a separate metal sheet can be placed in the undercut to at least partially fill the gap. The separate metal sheet (when used) can be designed to be removed from the undercut later; however, this is not necessary. The forging operation can be performed in the area of the medical device to be hardened. For circular or curved parts of the medical device, the forging can be rotational. For non-circular parts of the medical device, the forging of the non-circular part of the medical device can be performed by a non-rotating forging die. Instead of rotating or in addition to rotating, the die can optionally be made to vibrate in the radial and / or longitudinal directions. The medical device can optionally be forged in multiple directions in a single operation or multiple operations to obtain hardness at the desired location and / or orientation of the medical device. The forging temperature of a particular metal alloy can vary. For the metal alloy, if the forging is performed in air or an oxidizing environment, the forging temperature can be room temperature (RT) (e.g., 10 °C - 27 °C and all values and ranges therebetween) to about 400 °C (e.g., 10 °C - 400 °C and all values and ranges therebetween). If the forging process is performed in a controlled neutral or non-reducing environment (e.g., an inert environment), the forging temperature can be increased to at most about 1500 °C (e.g., 10 °C - 1500 °C and all values and ranges therebetween). The forging process can be performed by repeatedly hammering the medical device at the desired forging temperature at the location to be hardened. In a non-limiting embodiment, during the forging process, ions of boron and / or nitrogen are allowed to impinge on the rhenium atoms in the rhenium-containing metal alloy, thereby forming ReB2, ReN2, and / or ReN3; however, this is not necessary. It has been found that ReB2, ReN2, and / or ReN3 are superhard compounds. In a non-limiting method, when the metal is in a less hardened state, the metal for the medical device can be processed and formed into the medical device. Thus, the raw material can first be annealed to soften and then the metal can be processed into the desired shape. After the metal alloy is formed, the metal alloy can be re-hardened. The hardening of the metal alloy of the medical device improves the wear resistance and / or shape retention of the medical device. Medical metal alloys generally cannot be re-hardened by annealing, so a special re-hardening process is required. This re-hardening can be achieved by the forging process of the present disclosure.

[0124] According to another and / or alternative aspect of the present disclosure, the metal alloy may optionally be nitrided; however, this is not necessary. When forming the medical device partially or completely, during the optional drawing of the metal alloy, the nitride layer on the metal alloy may act as a lubricating surface. After the metal alloy is nitrided, the metal alloy is typically cleaned; however, this is not necessary. In the nitriding process, the surface of the metal alloy is modified due to the presence of nitrogen. The nitriding process can be gas nitriding, salt bath nitriding, or plasma nitriding. In gas nitriding, nitrogen diffuses into the surface of the metal alloy, thereby producing a nitride layer. The thickness and phase composition of the resulting nitride layer can be selected, and the process can be optimized for the specific properties required. Prior to the nitriding process, the metal alloy may optionally be exposed to argon and / or hydrogen to clean and / or preheat the metal alloy. These gases can optionally be used to clean the oxide layer and / or solvent from the surface of the metal alloy. During the nitriding process, the metal alloy may optionally be exposed to hydrogen to inhibit or prevent the formation of oxides on the surface of the metal alloy. The thickness of the nitrided surface layer is less than about 1 mm. In one non-limiting embodiment, the thickness of the nitride surface layer is at least about 50 nanometers and less than about 1 mm (and all values and ranges therebetween). In another non-limiting embodiment, the thickness of the nitrided surface layer is at least about 50 nanometers and less than about 0.1 mm. Generally, the weight percentage of nitrogen in the nitrided surface layer is 0.0001 wt% - 5 wt% nitrogen (and all values and ranges therebetween). In one non-limiting embodiment, the weight percentage of nitrogen in the nitrided surface layer is generally less than one of the main components of the metal alloy, and generally less than each of the two main components of the metal alloy. For example, when the metal alloy is nitrided, the weight percentage of nitrogen in the nitrided surface layer is less than the weight percentage of rhenium in the nitrided surface layer. In one non-limiting composition of the nitrided surface layer on the metal alloy (e.g., 47 wt% - 55 wt% rhenium, 10 wt% - 46 wt% molybdenum, 0.1 wt% - 30 wt% additional metal alloying agent), the nitrided surface layer contains at least 40 wt% rhenium, at least 8 wt% molybdenum, and 0.0001 wt% - 5 wt% nitrogen (and all values and ranges therebetween). The nitriding process for the metal alloy can be used to increase the surface hardness and / or wear resistance of the medical device, and / or inhibit or prevent discoloration of the metal alloy (e.g., discoloration caused by oxidation, etc.). For example, the nitriding process can be used to increase the wear resistance of the surface wear parts on the joint surface or the metal alloy used in the medical device to extend the life of the medical device, and / or increase the wear life of the mating surface on the medical device (e.g., the polyethylene liner of joint implants such as knees, hips, shoulders, etc.), and / or reduce the particulates generated due to the use of the medical device, and / or maintain the appearance of the outer surface of the metal alloy on the medical device.

[0125] According to another and / or alternative aspect of the present disclosure, just before or after the metal alloy is partially or fully formed into the desired medical device, it can optionally be cleaned, polished, disinfected, nitrided, etc. for the final processing of the metal alloy. In a non-limiting embodiment of the present disclosure, the metal alloy is electropolished. In a non-limiting aspect of this embodiment, the metal alloy is cleaned before being exposed to the polishing solution; however, this is not necessary.

[0126] According to another and / or alternative aspect of the present disclosure, the medical device may optionally comprise and / or be coated with one or more agents that facilitate the success of the medical device and / or the treatment area. The term "agent" includes, but is not limited to, substances, drugs, biologics, veterinary products, pharmaceuticals, and the like or derivatives thereof that are otherwise formulated and / or designed to prevent, inhibit, and / or treat one or more clinical and / or biological events, and / or promote healing. Non-limiting examples of clinical events that can be addressed by one or more agents include, but are not limited to, viral, fungal, and / or bacterial infections; vascular diseases and / or disorders, digestive diseases and / or disorders, reproductive diseases and / or disorders, lymphatic diseases and / or disorders, cancer, graft rejection, pain, nausea, swelling, arthritis, bone diseases and / or disorders, organ failure, immune diseases and / or disorders, cholesterol problems, blood diseases and / or disorders, pulmonary diseases and / or disorders, heart diseases and / or disorders, brain diseases and / or disorders, neuropathic diseases and / or disorders, kidney diseases and / or disorders, ulcers, liver diseases and / or disorders, intestinal diseases and / or disorders, gallbladder diseases and / or disorders, pancreatic diseases and / or disorders, psychological disorders, respiratory diseases and / or disorders, glandular diseases and / or disorders, skin diseases and / or disorders, hearing diseases and / or disorders, oral diseases and / or disorders, nasal diseases and / or disorders, eye diseases and / or disorders, fatigue, genetic diseases and / or disorders, burns, scars, and / or keloids, trauma, weight diseases and / or disorders, addictive diseases and / or disorders, hair loss, painful cramps, muscle spasms, tissue repair, nerve repair, nerve regeneration, and the like. The type and / or amount of the agent(s) incorporated in and / or coated on the medical device can vary. When two or more agents are incorporated in and / or coated on the medical device, the amounts of the two or more agents can be the same or different. The one or more agents can be coated on and / or impregnated in the medical device by a variety of mechanisms, such as, but not limited to, spraying (e.g., atomized spraying techniques, etc.), flame spraying, powder deposition, dip coating, flow coating, dip-spin coating, roll coating (direct and reverse), sonication, brush coating, plasma deposition, deposition by vapor deposition, MEMS techniques, and rotary die deposition. In another and / or alternative non-limiting embodiment of the present disclosure, the type and / or amount of the agent(s) incorporated on, in, and / or in combination with the medical device is typically selected for the treatment of one or more medical treatments. The amounts of two or more agents used on, in, and / or in combination with the medical device can be the same or different. When used on and / or in the medical device, the one or more agents can optionally be released in a controlled manner to provide the desired dose of the agent to the area to be treated over a sustained period of time. It is understood that it is not always necessary and / or desirable to control the release of the one or more agents on the medical device.Thus, during and / or after insertion of a medical device into a treatment area, one or more agents on and / or in the medical device may be released uncontrollably from the medical device. It is also understood that one or more agents on and / or in the medical device may be released controllably from the medical device, and that one or more agents on and / or in the medical device may be released uncontrollably from the medical device. It is further understood that one or more agents on and / or in one area of the medical device may be released controllably from the medical device, and that one or more agents on and / or in the medical device may be released uncontrollably from another area of the medical device. Thus, the medical device can be designed such that: 1) all agents on and / or in the medical device are released controllably, 2) some agents on and / or in the medical device are released controllably, and some agents on the medical device are released uncontrolled, or 3) all agents on and / or in the medical device are released uncontrollably. The medical device can also be designed such that the rate of release of one or more agents from the medical device is the same or different. The medical device can also be designed such that the rate of release of one or more agents from one or more areas of the medical device is the same or different. Non-limiting arrangements that can be used to control the release of one or more agents from the medical device include 1) at least partially coating one or more agents with one or more polymers, 2) at least partially incorporating one or more agents into one or more polymers and / or at least partially encapsulating one or more agents into one or more polymers and / or encapsulating with one or more polymers, and / or 3) inserting one or more agents into pores, channels, cavities, etc. in the medical device and at least partially coating or covering such pores, channels, cavities, etc. with one or more polymers. It is understood that other or additional devices can be used to control the release of one or more agents from the medical device. When used to at least partially control the release of one or more agents from the medical device, one or more polymers can be porous or non-porous. One or more agents can be inserted and / or applied into and / or onto one or more surface structures and / or microstructures on the medical device, and / or used to at least partially form one or more surface structures and / or microstructures on the medical device. Thus, one or more agents on the medical device can 1) be coated on one or more surface areas of the medical device, 2) be inserted and / or impregnated into one or more surface structures and / or microstructures, etc. on the medical device, and / or 3) form at least a part of the structure of the medical device or be included in at least a part of the structure of the medical device.When one or more agents are coated on a medical device, the one or more agents can: 1) be directly coated on one or more surfaces of the medical device; 2) be mixed with one or more coating polymers or other coating materials and then at least partially coated on one or more surfaces of the medical device; 3) be at least partially coated on the surface of another coating material that has been at least partially coated on the medical device; and / or 4) be at least partially encapsulated between a) the surface or region of the medical device and one or more other coating materials and / or b) between two or more other coating materials. It is understood that many other coating arrangements can be additionally or alternatively used. When one or more agents are optionally inserted and / or impregnated in one or more internal structures, surface structures, and / or microstructures of the medical device, 1) one or more other coating materials can be at least partially applied to one or more internal structures, surface structures, and / or microstructures of the medical device and / or 2) one or more polymers can be combined with one or more agents. Thus, the one or more agents can: 1) be embedded in the structure of the medical device; 2) be located in one or more internal structures of the medical device; 3) be encapsulated between two polymer coatings; 4) be encapsulated between the underlying structure and a polymer coating; 5) be mixed in the underlying structure of the medical device including at least one polymer coating; or 6) be one or more combinations of 1, 2, 3, 4, and / or 5. Additionally or alternatively, one or more coatings of one or more polymers on the medical device can include: 1) one or more coatings of non-porous polymers; 2) one or more coatings of a combination of one or more porous polymers and one or more non-porous polymers; 3) one or more coatings of porous polymers; or 4) one or more combinations of options 1, 2, and 3.

[0127] In another and / or alternative aspect of the present disclosure, different agents may optionally be located in different polymer coatings and / or between and / or on the structure of the medical device. It is also understood that many other and / or additional coating combinations and / or configurations may be used. The concentration of one or more agents, the type of polymer, the type and / or shape of the internal structure in the medical device, and / or the coating thickness of one or more agents may be used to control the release time, release rate, and / or dose of one or more agents; however, other or additional combinations may be used. Thus, the combinations of agents and polymer systems and their locations on the medical device can be diverse. It is also understood that one or more agents may be deposited on the top surface of the medical device to provide an initial uncontrolled burst release effect of one or more agents before 1) the controlled release of one or more agents through one or more layers of a polymer system comprising one or more non-porous polymers, and / or 2) the uncontrolled release of one or more agents through one or more layers of the polymer system. One or more agents and / or polymers may be coated on the medical device by a variety of mechanisms, such as but not limited to spraying (e.g., atomized spraying techniques, etc.), dip coating, roll coating, sonication, brush coating, plasma deposition, and / or deposition by chemical vapor deposition.

[0128] In another and / or alternative aspect of the present disclosure, a plurality of polymers may optionally be coated on a medical device and / or used to form at least a portion of a medical device. One or more polymers may be used on a medical device for a variety of reasons, such as but not limited to 1) forming a part of the medical device, 2) improving the physical properties of the medical device (e.g., improving strength, improving durability, improving biocompatibility, reducing friction, etc.), 3) forming a protective coating on one or more surface structures of the medical device, 4) at least partially forming one or more surface structures on the medical device, and / or 5) at least partially controlling the release rate of one or more agents from the medical device. It is understood that one or more polymers may have other or additional uses on a medical device. One or more polymers may be porous, non-porous, bio-stable, biodegradable (i.e., dissolve, degrade, absorb in vivo, or any combination thereof), and / or biocompatible. When a medical device is coated with one or more polymers, the polymer may include 1) one or more coatings of a non-porous polymer, 2) one or more coatings of a combination of one or more porous polymers and one or more non-porous polymers, 3) one or more coatings of one or more porous polymers and one or more coatings of one or more non-porous polymers, 4) one or more coatings of a porous polymer, or 5) one or more combinations of options 1, 2, 3, and 4. The thickness of one or more of the polymer layers may be the same or different. When one or more polymer layers are coated onto at least a portion of a medical device, the one or more coatings may be applied by a variety of techniques, such as but not limited to vapor deposition and / or plasma deposition, spraying, dip coating, roll coating, sonication, atomization, brush coating, and the like; however, other or additional coating techniques may be used. One or more polymers that may be coated on a medical device and / or used to at least partially form a medical device may be polymers that are considered biodegradable, bioresorbable, or bioerodible; polymers that are considered bio-stable; and / or polymers that can be made biodegradable and / or bioresorbable by modification. The thickness of each polymer layer is typically at least about 0.01 μm and typically less than about 150 μm (e.g., 0.01 μm to 150 μm and all values and ranges therebetween); however, other thicknesses may be used. In one non-limiting embodiment, the thickness of the polymer layer and / or the agent layer is about 0.02 μm - 75 μm, more particularly about 0.05 μm - 50 μm, and even more particularly about 1 μm - 30 μm. It is understood that other thicknesses may be used.

[0129] According to another and / or alternative aspect of the present disclosure, when a medical device comprises and / or is coated with one or more agents, the medical device may comprise and / or be coated with one or more agents that are the same or different in different regions of the medical device and / or have different amounts and / or concentrations in different regions of the medical device. For example, the medical device may 1) be coated with and / or contain one or more biologics on at least a portion of the medical device and at least another portion of the medical device is not coated with and / or does not contain an agent; 2) be coated with and / or contain one or more biologics that are different from one or more biologics on at least another portion of the medical device; and / or 3) be coated with and / or contain one or more biologic agents, the concentration of which is different from the concentration of one or more biologic agents on at least another portion of the medical device.

[0130] According to another and / or alternative aspect of the present disclosure, one or more portions of the medical device may optionally 1) contain the same or different agents, 2) contain the same or different amounts of one or more agents, 3) contain the same or different polymer coatings, 4) contain one or more polymer coatings with the same or different coating thicknesses, 5) cause one or more portions of the medical device to release one or more agents controllably and / or uncontrollably, and / or 6) cause one or more portions of the medical device to release one or more agents controllably and one or more portions of the medical device to release one or more agents uncontrollably.

[0131] According to another and / or alternative aspect of the present disclosure, one or more surfaces of the medical device may optionally be treated to achieve the desired coating properties of one or more agents and one or more polymers coated on the medical device. Such surface treatment techniques include, but are not limited to, cleaning, polishing, smoothing, nitriding, annealing, forging, cold working, etching (chemical etching, plasma etching, etc.), and the like. It is understood that other or additional surface treatment methods may be used before coating one or more agents and / or polymers on the surface of the medical device.

[0132] In another and / or alternative non-limiting aspect of the present disclosure, the medical device may optionally include a marker material that facilitates proper positioning of the medical device within a body passageway. The marker material is typically designed to be visible to electromagnetic waves (e.g., x-rays, microwaves, visible light, infrared waves, ultraviolet light, etc.); sound waves (e.g., ultrasonic waves, etc.); magnetic waves (e.g., MRI, etc.); and / or other types of electromagnetic waves (e.g., microwaves, visible light, infrared waves, ultraviolet waves, etc.). The marker material may form all or a portion of the medical device and / or be coated on one or more portions of the medical device (the flared portion and / or the body portion, at the distal end of the medical device, at or near the transition between the body portion and the flared portion, etc.). The location of the marker material may be at one or more locations on the medical device. The size of one or more regions containing the marker material may be the same or different. The marker materials may be spaced apart by a defined distance to form a ruler-like marking on the medical device, thereby facilitating positioning of the medical device within the body passageway. The marker material may be a rigid or flexible material. The marker material may be a bio-stable or biodegradable material.

[0133] In another and / or alternative aspect of the present disclosure, the medical device or one or more regions of the medical device may optionally be constructed by using one or more microelectromechanical manufacturing (MEMS) techniques (e.g., micromachining, laser micromachining, micro molding, etc.); however, other or additional manufacturing techniques may be used.

[0134] In another and / or alternative aspect of the present disclosure, the medical device may optionally include one or more surface structures (e.g., pores, channels, pits, ribs, grooves, notches, ridges, teeth, needles, holes, cavities, depressions, etc.). These structures may be formed at least in part by MEMS (e.g., micromachining, etc.) techniques and / or other types of techniques.

[0135] According to another and / or alternative aspect of the present disclosure, a medical device may optionally include one or more microstructures (e.g., microneedles, micropores, microcylinders, microcones, microprisms, microtubes, microparallelepipeds, microprisms, microhemispheres, teeth, ribs, ridges, ratchets, hinges, zippers, zipper-like structures, etc.) on the surface of the medical device. As defined herein, a "microstructure" is a structure having at least one dimension (e.g., average width, average diameter, average height, average length, average depth, etc.) that does not exceed about 2 mm and typically does not exceed about 1 mm. It will be understood that when a medical device includes one or more surface structures, 1) all of the surface structures may be microstructures, 2) all of the surface structures may be non-microstructures, or 3) a portion of the surface structures may be microstructures while a portion may be non-microstructures. Generally, the microstructures (when formed) extend from or into the outer surface by no more than about 400 microns (0.01 microns - 400 microns and all values and ranges therebetween), and more typically less than about 300 microns, and more typically about 15 microns - 250 microns; however, other sizes may be used. The microstructures may be aggregated or distributed over the entire surface of the medical device. Microstructures and / or surface structures of similar shape and / or size may be used, or microstructures of different shapes and / or sizes may be used. When one or more surface structures and / or microstructures are designed to extend from the surface of the medical device, the one or more surface structures and / or microstructures may be formed in the extended position and / or designed to extend from the medical device during and / or after deployment of the medical device in the treatment area. The microstructures and / or surface structures may be designed to contain and / or be fluidly connected to channels, cavities, etc.; however, this is not required. Once the medical device has been positioned on and / or within a patient, one or more surface structures and / or microstructures may be used to engage and / or penetrate surrounding tissue or organs; however, this is not required. One or more surface structures and / or microstructures may be used to facilitate the formation and maintenance of the shape of the medical device. In one non-limiting embodiment, one or more surface structures and / or microstructures may be formed at least in part from a medicament and / or from a polymer. One or more of the surface structures and / or microstructures may include one or more internal channels that may contain one or more materials (e.g., medicaments, polymers, etc.); however, this is not required. One or more coatings of the medical device and / or one or more surface structures and / or microstructures may be used for a variety of purposes, such as but not limited to 1) increasing the binding and / or adhesion of one or more medicaments, adhesives, marker materials, and / or polymers to the medical device, 2) altering the appearance or surface properties of the medical device, and / or 3) controlling the release rate of one or more medicaments. One or more microstructures and / or surface structures may be biostable, biodegradable, etc.A medical device or one or more regions of a medical device may be at least partially covered with a protective material and / or filled with a protective material to at least partially protect one or more regions of the medical device and / or one or more microstructures and / or surface structures on the medical device from damage. The protective material may include one or more of the above polymers. The protective material may be 1) biostable and / or biodegradable and / or 2) porous and / or non-porous.

[0136] In another and / or alternative aspect of the present disclosure, the medical device may optionally be an expandable device that may be expanded by using some other device (e.g., a balloon, etc.). The expandable medical device may be made of a material that does not have or substantially does not have shape memory properties.

[0137] According to another and / or alternative aspect of the present disclosure, a near-net shaping process for a frame or other metal component of a medical device is optionally provided. In a non-limiting embodiment of the present disclosure, a method of providing a powder compacting material and increasing the strength after sintering by applying additional cold working is provided. In a non-limiting embodiment, a green part is pressed and then sintered. Thereafter, the sintered part is pressed again to increase its mechanical strength by cold working the pressed and sintered part. Generally, the temperature during the pressing process after the sintering process is 20°C - 100°C (and all values and ranges therebetween), typically 20°C - 80°C, and more typically 20°C - 40°C. As defined herein, cold working occurs at a temperature not exceeding 150°C (e.g., 10°C - 150°C and all values and ranges therebetween). It is necessary to determine the shape change of the sintered part after pressing so that the final part (pressed, sintered, and repressed) meets the dimensional requirements of the finally formed part. A method of increasing the mechanical strength of a pressed metal part is also provided, which increases its mechanical strength by repressing the sintered part to perform additional cold working on the material. A method of using metal powder to press the powder into a near-net or final part is also provided. In a non-limiting embodiment, a method of manufacturing a metal part with a predetermined void to produce a trabecular or foamy structure is provided, which includes mixing metal and polymer powders, pressing the powders into a finished part or a semi-finished green part, and then sintering the part under conditions where the polymer leaves the metal through the thermal degradation process of the polymer. The porosity of the resulting part is related to the size of the polymer particles and the uniformity of the mixture during pressing before sintering. In another non-limiting embodiment, a method is provided by which the residue of the polymer remains on the metal substrate after thermal degradation, and the polymer residue has some desired biological effects (e.g., masking the metal from the body by encapsulation, promoting cell attachment and growth). The polymer and metal powders can have different sizes to create multiple voids - some large voids create channels for cell growth, and some small voids create a ruff surface that promotes cell attachment. It is understood that the polymer can be dispersed uniformly or non-uniformly with the metal powder. For example, if the finally formed part has a uniform density and pore structure, the polymer material is uniformly dispersed with the metal powder before consolidating and pressing the polymer and metal powders together and then sintering the metal powders together to form a metal part or a medical device.Alternatively, if the formed metal part or medical device has one or more channels, passageways, and / or voids on the outer surface and / or within the formed part or medical device, at least a portion of the polymer is not uniformly distributed with the metal powder but instead aggregates or forms all of the areas that will become one or more channels, passageways, and / or voids on the outer surface and / or within the formed part or medical device such that when the polymer and metal powder are sintered, some or all of the polymer degrades and is removed from the part or medical device, thereby forming such one or more channels, passageways, and / or voids on the outer surface and / or within the formed part or medical device. Thus, the combined use of the polymer and metal powder and subsequent pressing and sintering can be used to form novel and customized shapes or near-net forms of medical devices. Generally, prior to the sintering step, the polymer comprises from about 0.1 vol% to 70 vol% (and all values and ranges therebetween) of the consolidated and pressed material, and generally, prior to the sintering step, the polymer comprises from about 1 vol% to 60 vol% of the consolidated and pressed material.

[0138] According to another and / or alternative aspect of the present disclosure, the metal alloy for at least partially forming a medical device is initially formed as a billet, rod, tube, etc., and then machined into a final form through one or more finishing processes. The metal alloy billet, rod, tube, etc. can be formed by various techniques, such as but not limited to 1) melting the metal alloy and / or the metals forming the metal alloy (e.g., vacuum arc melting, etc.), and then extruding and / or casting the metal alloy into a billet, rod, tube, etc., 2) melting the metal alloy and / or the metals forming the metal alloy, forming a metal strip, and then rolling and welding the strip into a billet, rod, tube, etc., 3) consolidating the metal powder of the metal alloy and / or the metal powder of the metals forming the metal alloy into a billet, rod, tube, etc., or 4) 3-D printing the metal powder of the metal alloy and / or the metal powder of the metals forming the metal alloy into a billet, rod, tube, etc. When the metal alloy is formed as a billet, the shape and size of the billet are not restrictive. In one non-restrictive process, near net medical devices, near net components of medical devices, billets, rods, tubes, etc. can be formed from one or more metal or metal alloy ingots. In one non-restrictive process, an arc melting process (e.g., vacuum arc melting process, etc.) can be used to form near net medical devices, near net components of medical devices, billets, rods, tubes, etc. In one non-restrictive embodiment, the average particle size of the metal powder is less than about 230 mesh (e.g., less than 63 microns; 1 micron - 62 microns and all values and ranges therebetween). In another and / or alternative non-restrictive embodiment, the average particle size of the metal powder is about 2 microns - 62 microns, and more particularly about 5 microns - 49.9 microns. In another and / or alternative non-restrictive embodiment, the average particle size of the metal powder is about 10 microns - 40 microns. In another and / or alternative non-restrictive embodiment, the average density of the metal powder is greater than 5 g / cm 3 (e.g., 5.001 g / cm 3 to 19.3 g / cm 3 and all values and ranges therebetween). In another and / or alternative non-restrictive embodiment, 10 vol% - 100 vol% (and all values and ranges therebetween) of the metal powder is spherical. The purity of the metal powder should be selected such that the metal powder contains very low levels of carbon, oxygen, and nitrogen. Generally, the carbon content of the metal powder used to form the metal alloy is less than about 100 ppm, the oxygen content is less than about 50 ppm, and the nitrogen content is less than about 20 ppm. Generally, the metal powder used to form the metal alloy has a purity grade of at least 99.9 and more typically at least about 99.95.

[0139] According to another and / or alternative aspect of the present disclosure, when metal powder is consolidated to form a metal alloy into a billet, rod, tube, etc., the metal powder is pressed together to form a solid solution of the metal alloy into a near-net medical device, a near-net component of a medical device, a billet, a rod, a tube, etc. Generally, the pressing process is carried out by an isostatic pressing process (i.e., applying uniform pressure to the metal powder from all sides); however, other processes can be used. When the metal powder is isostatically pressed together, cold isostatic pressing (CIP) is usually used to consolidate the metal powder; however, this is not necessary. The pressing process can be carried out in an inert atmosphere, an oxygen-reducing atmosphere (such as hydrogen, argon, and a mixture of hydrogen and argon, etc.) and / or under vacuum; however, this is not necessary. The average density of the near-net medical device, the near-net component of the medical device, the billet, the rod, the tube, etc. obtained by pressing the metal powder together is 80%-95% (and all values and ranges therebetween) of the final average density of the near-net medical device, the near-net component of the medical device, the billet, the rod, the tube, etc. or about 70%-96% (and all values and ranges therebetween) of the minimum theoretical density of the metal alloy. A pressing pressure of at least about 300 MPa is usually used. Generally, the pressing pressure is about 400 MPa - 700 MPa; however, other pressures can be used. After the metal powder is pressed together, the pressed metal powder is sintered to partially or completely fuse the metal powder together to form a near-net medical device, a near-net component of a medical device, a billet, a rod, a tube, etc. The sintering of the consolidated metal powder can be carried out in an oxygen-reducing atmosphere (such as helium, argon, hydrogen, a mixture of argon and hydrogen, etc.) and / or under vacuum; however, this is not necessary. At a high sintering temperature, a high hydrogen atmosphere will reduce the amount of carbon and oxygen in the formed near-net medical device, the near-net component of the medical device, the billet, the rod, the tube, etc. The sintered metal powder generally has a sintered-state average density of about 90%-99% of the minimum theoretical density of the metal alloy.

[0140] According to another and / or alternative aspect of the present disclosure, when metal powder is used for 3D printing a medical device, a component of a medical device, a billet, a rod, a tube, etc., the average particle size of the metal powder is optionally 2 microns - 62 microns, and more specifically about 5 microns - 49.9 microns, the average density of the metal powder is greater than 5 g / cm 3 , and the metal powder is generally spherical, and the Hall flow rate (s / 50 g) is less than 30 seconds (such as 2 seconds - 29.99 seconds and all values and ranges therebetween).

[0141] According to another and / or alternative aspect of the present disclosure, after a near-net medical device, a near-net component of a medical device, a billet, a rod, a tube, etc. has been formed, the near-net medical device, the near-net component of the medical device, the billet, the rod, the tube, etc. can be optionally cleaned and / or polished; however, this is not necessary.

[0142] According to another and / or alternative aspect of the present disclosure, near-net medical devices, near-net components of medical devices, blanks, rods, tubes, etc. can be sized to the desired size of the medical device. In one non-limiting embodiment, the cross-sectional area or diameter of the near-net medical device, near-net component of the medical device, blank, rod, tube, etc. is reduced to the size of the final near-net medical device, near-net component of the medical device, blank, rod, tube, etc. in a single step or through a series of steps. The outer cross-sectional area or diameter of the near-net medical device, near-net component of the medical device, blank, rod, tube, etc. can be reduced by centerless grinding, turning, electropolishing, drawing processes, grinding, laser cutting, scraping, polishing, EDM cutting, etc. The outer cross-sectional area or diameter size of the near-net medical device, near-net component of the medical device, blank, rod, tube, etc. can be reduced by using one or more drawing processes; however, this is not necessary. During the drawing process, care should be taken not to form microcracks in the near-net medical device, near-net component of the medical device, blank, rod, tube, etc. during the reduction of the outer cross-sectional area or diameter.

[0143] According to another and / or alternative aspect of the present disclosure, the near-net medical device, near-net component of the medical device, blank, rod, tube, etc. can optionally be nitrided during the drawing process; however, this is not necessary. The nitrided layer on the near-net medical device, near-net component of the medical device, blank, rod, tube, etc. can act as a lubricating surface during the drawing process to facilitate the drawing of the near-net medical device, near-net component of the medical device, blank, rod, tube, etc. The near-net medical device, near-net component of the medical device, blank, rod, tube, etc. is typically nitrided in the presence of nitrogen or a nitrogen mixture.

[0144] Using a metal alloy to form all or part of a medical device can result in several advantages over medical devices formed from other materials. These advantages include, but are not limited to:

[0145] · Compared to standard stainless steel or standard chromium-cobalt alloy or standard titanium alloy, the metal alloy has increased strength and / or hardness. Therefore, compared to medical devices formed from different metals, a smaller amount of the metal alloy can be used in the medical device to obtain similar strength. Thus, by using the metal alloy, the resulting medical device can be made smaller and more compact without sacrificing the strength and durability of the medical device. The medical device can also have a smaller profile and thus can be inserted into smaller areas, openings, and / or channels. Thinner metal alloy struts can be used to form the frame or other parts of the medical device, which have the strength that would require thicker struts or other structures of the medical device when formed from standard stainless steel, standard chromium-cobalt alloy, or standard titanium alloy.

[0146] · The increased strength of the metal alloy also results in an increase in the radial strength of the medical device. For example, compared to a thick-walled medical device formed from standard stainless steel, standard cobalt-chromium alloy, or standard titanium alloy, the thickness of the wall of the medical device can be made thinner and similar or improved radial strength can be obtained.

[0147] · Compared to standard stainless steel or standard cobalt-chromium alloy, the metal alloy has improved stress-strain characteristics, bendability characteristics, elongation characteristics, and / or flexibility characteristics of the medical device, thus resulting in an extended lifespan of the medical device. For example, the medical device can be used in areas where the medical device is subjected to repeated bending. Due to the improved physical properties of the medical device made of the metal alloy, the medical device has improved fracture resistance in such frequently bent environments. These improved physical properties are caused at least in part by the composition of the metal alloy, the grain size of the metal alloy, the carbon, oxygen, and nitrogen content of the metal alloy, and / or the carbon / oxygen ratio of the metal alloy.

[0148] · Compared to standard stainless steel, standard cobalt-chromium alloy, or standard titanium alloy, the metal alloy can have a reduced degree of springback during crimping and / or dilation of the medical device. Due to the use of the metal alloy, the medical device formed from the metal alloy better maintains its crimped form and / or better maintains its dilated form after dilation. Therefore, when the medical device is crimped, when the medical device is mounted on a delivery device, and during insertion of the medical device into a body passage, the medical device better maintains its smaller profile. In addition, the medical device better maintains its dilated profile after dilation to contribute to the success of the medical device in the treatment area.

[0149] · Compared to a medical device formed from standard stainless steel, standard cobalt-chromium alloy, or standard titanium alloy, the use of the metal alloy in the medical device can cause the medical device to better conform to an irregularly shaped body passage when the medical device is dilated in the body passage.

[0150] · Compared to cold working of standard stainless steel, standard cobalt-chromium alloy, or standard titanium alloy, the metal alloy can have improved fatigue ductility when subjected to cold working.

[0151] · Compared to standard stainless steel, standard cobalt-chromium alloy, or standard titanium alloy, the metal alloy can have improved durability.

[0152] · Compared to standard stainless steel, standard cobalt-chromium alloy, or standard titanium alloy, the metal alloy can have improved hydrophilicity.

[0153] · Compared to standard stainless steel, standard cobalt-chromium alloy, or standard titanium alloy, the metal alloy can have reduced ion release in the body passage.

[0154] · Compared with standard stainless steel, standard cobalt-chromium alloy, or standard titanium alloy, the metal alloy may be less irritating to the body, thus reducing inflammation, accelerating healing, and increasing the success rate of medical devices.

[0155] Compared with expandable frames formed from standard stainless steel, standard cobalt-chromium alloy, and standard TiAlV alloy, a medical device including an expandable metal frame formed at least in part from a metal alloy may exhibit reduced springback, improved bending consistency, and greater radial strength, resulting in the following non-limiting advantages compared to expandable frames formed from standard stainless steel, standard cobalt-chromium alloy, or standard TiAlV alloy: 1) forming a frame of a medical device with thinner struts, struts, and / or strut junctions, which results in i) safer vascular access when inserting the medical device through a body passage into the treatment area, and / or ii) a reduced risk of bleeding and / or injury to the body passage and / or treatment area when the medical device is delivered to and / or expanded at the treatment area; 2) easier delivery of the medical device to the treatment area, which may result in i) reduced trauma to the body passage (e.g., blood vessel, aortic arch trauma, etc.) during insertion and / or expansion of the medical device at the treatment area, and / or ii) a reduced risk of neurological complications - stroke; 3) less springback, which results in i) a reduced crimp profile size, ii) increased consistency of the expanded medical device at the treatment area after expansion in the treatment area, iii) increased radial strength of the frame of the medical device after expansion at the treatment area, iv) only requiring a single crimp cycle to crimp the medical device onto a balloon catheter or other type of delivery device, v) a reduced incidence of damage to the components of the medical device (e.g., struts, struts, strut junctions, and / or other components of the expandable frame, leaflets, skirts, coatings, etc.) during crimping, expansion, and manipulation of the medical device, vi) a larger effective orifice area (EOA) of the medical device after expansion of the medical device, vi) reduced pulmonary valve regurgitation (PVR) after the medical device is expanded in the treatment area, and / or vii) only requiring a single expansion cycle of the balloon on the balloon catheter or other expansion mechanism to fully expand the medical device; and / or 4) manufacturing a medical device with excellent material biocompatibility to i) improve tissue adhesion and / or growth on or around the medical device, ii) reduce adverse tissue reactions to the medical device, iii) reduce the toxicity of the medical device, iv) potentially reduce thrombus formation within the valve during the life of the medical device, and / or v) reduce the incidence of infection during the life of the medical device.

[0156] Medical devices comprising a metallic alloy according to the present disclosure, such as expandable medical devices (e.g., expandable heart valves, stents, etc.), can overcome several unmet needs present in expandable medical devices formed from standard cobalt-chromium alloys, standard TiAlV alloys, and standard stainless steels, namely: 1) not having to form large pores in the large arterial vessels or other blood vessels to initially insert the crimped medical device into the atrial vessels or other blood vessels, thereby reducing the incidence of fatal bleeding during treatment; 2) enabling the medical device to be delivered and implanted into abnormally shaped heart valves or delivered and implanted through abnormally shaped arterial vessels; 3) reducing the incidence of paravalvular leakage and / or other types of leakage around the implanted medical device when the medical device is expanded; 4) increasing the radial strength of the expansion struts, columns, and / or strut joints in the expandable frame, and the strength of the expandable frame itself after the medical device is expanded; 5) reducing the amount of springback of the expandable frame during crimping and / or expansion of the medical device; 6) enabling the medical device to be used in a heart with a permanent pacemaker; 7) reducing the incidence of minor strokes during insertion and manipulation of the medical device at the treatment site; 8) reducing the incidence of damage to the coronary ostia; 9) improving fluoroscopic foreshortening; 10) further reducing aortic valve calcification and / or vascular calcification after implanting the medical device; 11) reducing the need for multiple crimping cycles when inserting the medical device onto a catheter or other type of delivery system; 12) reducing the incidence of frame / stent fractures during crimping and / or expansion of the medical device; 13) reducing the incidence of biofilm-endocarditis after implanting the medical device; 14) reducing allergic reactions to the medical device after implanting the medical device; 15) improving the hydrophilicity of the medical device to improve tissue growth on and / or around the implanted medical device; 16) reducing the magnetic susceptibility of the medical device; 17) reducing the toxicity of the medical device; 18) reducing the amount of metal ions released from the medical device, and / or 19) extending the lifespan of the leaflets and / or stents / frames and / or other components of the medical device after insertion of the medical device.

[0157] One non-limiting objective of the present disclosure is to provide a metallic alloy according to the present disclosure that exhibits a rhenium effect and can optionally be used to partially or fully form a medical device.

[0158] Another and / or alternative non-limiting objective of the present disclosure is to provide a metallic alloy according to the present disclosure that exhibits a rhenium effect and contains at least 15 atomic weight % rhenium.

[0159] Another and / or alternative non-limiting objective of the present disclosure is to provide a method and process for forming a metallic alloy according to the present disclosure that exhibits a rhenium effect and inhibits or prevents the formation of microcracks during processing of the metallic alloy.

[0160] Another and / or alternative non - limiting objective of the present disclosure is to provide a medical device that is partially or fully formed of a metal alloy according to the present disclosure, the metal alloy exhibits a rhenium effect, and wherein the medical device has improved physical properties.

[0161] Another and / or alternative non - limiting objective of the present disclosure is to provide a medical device that is at least partially formed of a metal alloy according to the present disclosure, the metal alloy exhibits a rhenium effect, and wherein the medical device has increased strength and / or hardness.

[0162] Another and / or alternative non - limiting objective of the present disclosure is to provide a method and process for forming a metal alloy according to the present disclosure, the metal alloy exhibits a rhenium effect and inhibits or prevents crack propagation and / or fatigue failure of the metal alloy.

[0163] Another and / or alternative non - limiting objective of the present disclosure is to provide a metal alloy that exhibits a rhenium effect, and wherein the metal alloy contains rhenium, molybdenum, and one or more additional additives.

[0164] Another and / or alternative non - limiting objective of the present disclosure is to provide a metal alloy that exhibits a rhenium effect, and wherein the metal alloy contains rhenium, molybdenum, chromium, and optionally one or more additional additives.

[0165] Another and / or alternative non - limiting objective of the present disclosure is to provide a medical device that contains a metal alloy that exhibits a rhenium effect, and wherein the metal alloy contains rhenium, molybdenum, and one or more additional additives; and wherein the medical device optionally includes an expandable frame.

[0166] Another and / or alternative non - limiting objective of the present disclosure is to provide a medical device that contains a metal alloy that exhibits a rhenium effect, and wherein the metal alloy contains rhenium, molybdenum, chromium, and optionally one or more additional additives; and wherein the medical device optionally includes an expandable frame.

[0167] Another and / or alternative non - limiting objective of the present disclosure is to provide a medical device that contains a metal alloy that exhibits a rhenium effect, and wherein the metal alloy contains rhenium, molybdenum, and one or more additional additives; and wherein the medical device optionally includes an expandable frame; and wherein the expandable frame includes a plurality of struts.

[0168] Another and / or alternative non - limiting objective of the present disclosure is to provide a medical device that contains a metal alloy that exhibits a rhenium effect, and wherein the metal alloy contains rhenium, molybdenum, chromium, and optionally one or more additional additives; and wherein the medical device optionally includes an expandable frame; wherein the expandable frame includes a plurality of struts.

[0169] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device comprising a metallic alloy, wherein the metallic alloy exhibits a rhenium effect and the metallic alloy comprises rhenium, molybdenum, and one or more alloying metals; and wherein the medical device includes an expandable frame; wherein the expandable frame is configured to be crimped to a crimped state such that the maximum outer diameter of the expandable frame in the crimped state is less than the maximum outer diameter of the expandable frame when fully expanded to an expanded state.

[0170] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device comprising a metallic alloy, wherein the metallic alloy exhibits a rhenium effect, and the metallic alloy comprises rhenium, molybdenum, chromium, and optionally one or more alloying metals; and wherein the medical device includes an expandable frame; wherein the expandable frame is configured to be crimped to a crimped state such that the maximum outer diameter of the expandable frame in the crimped state is less than the maximum outer diameter of the expandable frame when fully expanded to an expanded state.

[0171] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device comprising a metallic alloy that exhibits a rhenium effect, and wherein the metallic alloy comprises rhenium, molybdenum, and one or more alloying metals; and wherein the medical device includes an expandable frame; wherein the expandable frame has a springback of less than 5% after undergoing a first crimping process.

[0172] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device comprising a metallic alloy that exhibits a rhenium effect, and wherein the metallic alloy comprises rhenium, molybdenum, chromium, and optionally one or more alloying metals; and wherein the medical device includes an expandable frame; wherein the expandable frame has a springback of less than 5% after undergoing a first crimping process.

[0173] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device comprising a metallic alloy that exhibits a rhenium effect, and wherein the metallic alloy comprises rhenium, molybdenum, and one or more alloying metals; and wherein the medical device includes an expandable frame; wherein the expandable frame has a springback of less than 5% after expanding from a crimped state to an expanded state.

[0174] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device comprising a metallic alloy that exhibits a rhenium effect, and wherein the metallic alloy comprises rhenium, molybdenum, chromium, and optionally one or more alloying metals; and wherein the medical device includes an expandable frame; wherein the expandable frame has a springback of less than 5% after expanding from a crimped state to an expanded state.

[0175] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device that includes a metal alloy exhibiting a rhenium effect, and wherein the metal alloy includes rhenium, molybdenum, and one or more alloying metals; and wherein the metal alloy has hydrophilicity, and the contact angle of a water droplet on the surface of the metal alloy is 25° - 45° (and all values and ranges therebetween).

[0176] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device that includes a metal alloy exhibiting a rhenium effect, and wherein the metal alloy includes rhenium, molybdenum, and one or more alloying metals; and wherein the maximum ion release of the main components of the metal alloy does not exceed 0.5 μg / cm per day when the metal alloy is inserted or implanted onto or into a patient's body. 2 ; and wherein the main component of the rhenium alloy is the metal in the rhenium alloy, which accounts for at least 2% by weight of the metal alloy.

[0177] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device that includes a metal alloy exhibiting a rhenium effect, and wherein the metal alloy includes rhenium, molybdenum, and one or more alloying metals; and wherein the absolute increase in ion release per dose of the metal alloy in the tissue around the medical device does not exceed 50 days after the metal alloy is inserted or implanted onto or into the patient's body.

[0178] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device that includes a metal alloy exhibiting a rhenium effect, and wherein the medical device is a expandable stent or an expandable artificial heart valve.

[0179] Another and / or alternative non-limiting object of the present disclosure is to provide a medical device that can be formed by one or more manufacturing processes. These manufacturing processes may include, but are not limited to, laser cutting, etching, annealing, drawing, Pilger rolling, electroplating, electropolishing, machining, plasma coating, 3D printing coating, 3D printing, chemical vapor deposition, chemical polishing, cleaning, pickling, ion beam deposition or implantation, sputter coating, vacuum deposition, etc. In a non-limiting embodiment, at least a part or all of the medical device is formed by a 3D printing process.

[0180] Another and / or alternative non-limiting object of the present disclosure is to provide a metallic alloy that includes a unique combination of metals that exhibits a "rhenium effect" and results in 1) a medical device having a desired high ductility at about room temperature, 2) a medical device having a desired tensile elongation, 3) a homogeneous or solid solution of a metallic alloy having high radiopacity, 4) reducing or preventing the formation of microcracks and / or fracture of the metallic alloy of the tube of the present disclosure when the tube is sized and / or cut to form a medical device or a part of a medical device (e.g., the frame of a medical device, etc.), 5) reducing or preventing the formation of microcracks and / or fracture of a medical device or a part of a medical device (e.g., the frame of a medical device, etc.) when the medical device or a part of a medical device (e.g., the frame of a medical device, etc.) is crimped, 6) reducing or preventing the formation of microcracks and / or fracture of a medical device or a part of a medical device (e.g., the frame of a medical device, etc.) when the medical device is bent and / or expanded in a body passage, 7) a medical device having a desired ultimate tensile strength and yield strength, 8) a medical device or a part of a medical device (e.g., the frame of a medical device, etc.) having a very thin wall thickness and still having a desired radial force required to keep the medical device or a part of a medical device (e.g., the frame of a medical device, etc.) in an open state when expanded, 9) a medical device or a part of a medical device (e.g., the frame of a medical device, etc.) that exhibits less springback when the medical device or a part of a medical device (e.g., the frame of a medical device, etc.) is crimped onto a delivery system and / or expanded in a body passage, 10) a medical device that exhibits improved conformance to the shape of a treatment area in a body passage when the medical device is expanded in the body passage, 11) a medical device that exhibits improved fatigue ductility, 12) a medical device that exhibits reduced fluoroscopic foreshortening when expanded, and / or 13) a medical device that exhibits improved durability.

[0181] Another and / or alternative non-limiting object of the present disclosure is to provide a metallic alloy in which the average grain size of the metallic alloy that exhibits the rhenium effect can be about 4 ASTM - 20 ASTM, the tensile elongation of the metallic alloy can be about 25% - 50%, the average density of the metallic alloy can be at least about 5 gm / cc, the average yield strength of the metallic alloy can be about 70 - 250 (ksi), the average ultimate tensile strength of the metallic alloy can be about 80 UTS - 550 UTS (ksi), and the average Vickers hardness can be 234 DPH to 700 DPH, or the Rockwell C hardness at 77°F is 19 - 60; however, this is not required.

[0182] Another and / or alternative non-limiting object of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % of rhenium; and wherein the metal alloy comprises one or more alloying metals selected from the group consisting of aluminum, bismuth, chromium, cobalt, copper, hafnium, iridium, iron, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, and zirconium; and wherein the metal alloy a) has at least a 10% increase in ductility compared to the metal alloy without rhenium, and / or b) has at least a 10% increase in tensile strength.

[0183] Another and / or alternative non-limiting object of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % of rhenium and less than 50 wt% rhenium; and wherein the metal alloy comprises one or more alloying metals selected from the group consisting of aluminum, bismuth, chromium, cobalt, copper, hafnium, iridium, iron, magnesium, manganese, molybdenum, nickel, niobium, osmium, platinum, rhodium, ruthenium, silicon, silver, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, and zirconium; and wherein the metal alloy a) has at least a 10% increase in ductility compared to the metal alloy without rhenium, and / or b) has at least a 10% increase in tensile strength.

[0184] Another and / or alternative non-limiting object of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % rhenium and 50 wt% - 78 wt% iron (and all values and ranges therebetween), and a) 9 wt% - 27 wt% chromium (and all values and ranges therebetween), b) 0.1 wt% - 26 wt% nickel (and all values and ranges therebetween), c) 0.01 wt% - 7 wt% molybdenum (and all values and ranges therebetween), d) 0.01 wt% - 16 wt% manganese (and all values and ranges therebetween), e) 0.01 wt% - 4 wt% silicon (and all values and ranges therebetween), f) 0.01 wt% - 2 wt% titanium (and all values and ranges therebetween), g) 0.01 wt% - 1 wt% selenium (and all values and ranges therebetween), h) 0.01 wt% - 1 wt% niobium (and all values and ranges therebetween), i) 0.01 wt% - 2 wt% aluminum (and all values and ranges therebetween), j) 0.01 wt% - 1 wt% tantalum (and all values and ranges therebetween), k) 0.01 wt% - 1 wt% cobalt (and all values and ranges therebetween), l) 0.01 wt% - 5 wt% copper (and all values and ranges therebetween), m) 0.01 wt% - 1 wt% vanadium (and all values and ranges therebetween), and n) 0.01 wt% - 2 wt% tungsten (and all values and ranges therebetween) or more.

[0185] Another and / or alternative non-limiting object of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % rhenium and 35 wt % - 68 wt % cobalt (and all values and ranges therebetween), and a) 12 wt % - 28 wt % chromium (and all values and ranges therebetween), b) 0.01 wt % - 38 wt % nickel (and all values and ranges therebetween), c) 0.1 wt % - 30 wt % molybdenum (and all values and ranges therebetween), d) 0.01 wt % - 2 wt % manganese (and all values and ranges therebetween), e) 0.01 wt % - 1 wt % silicon (and all values and ranges therebetween), f) 0.01 wt % - 18 wt % tungsten (and all values and ranges therebetween), g) 0.01 wt % - 0.5 wt % lanthanum (and all values and ranges therebetween), h) 0.01 wt % - 20 wt % iron (and all values and ranges therebetween), i) 0.01 wt % - 5 wt % titanium (and all values and ranges therebetween), j) 0.01 wt % - 2 wt % niobium (and all values and ranges therebetween), k) 0.01 wt % - 2 wt % aluminum (and all values and ranges therebetween), l) 0.01 wt % - 1 wt % silicon (and all values and ranges therebetween), m) 0.01 wt % - 0.5 wt % boron (and all values and ranges therebetween), and n) one or more of 0.01 wt % - 0.5 wt % silver (and all values and ranges therebetween).

[0186] Another and / or alternative non-limiting object of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % rhenium and 70 wt % - 91.5 wt % titanium (and all values and ranges therebetween), and a) 2 wt % - 8 wt % aluminum (and all values and ranges therebetween), b) 0.01 wt % - 16 wt % vanadium (and all values and ranges therebetween), c) 0.01 wt % - 1 wt % iron (and all values and ranges therebetween), d) 0.01 wt % - 0.5 wt % yttrium (and all values and ranges therebetween), e) 0.01 wt % - 20 wt % chromium (and all values and ranges therebetween), f) 0.0 wt % - 16 wt % molybdenum (and all values and ranges therebetween), g) 0.01 wt % - 2 wt % nickel (and all values and ranges therebetween), h) 0.01 wt % - 12 wt % tin (and all values and ranges therebetween), i) 0.01 wt % - 6 wt % zirconium (and all values and ranges therebetween), j) 0.01 wt % - 2 wt % tantalum (and all values and ranges therebetween), k) 0.01 wt % - 4 wt % niobium (and all values and ranges therebetween), l) 0.01 wt % - 1 wt % silicon (and all values and ranges therebetween), m) 0.01 wt % - 3 wt % iron (and all values and ranges therebetween).

[0187] Another and / or alternative non - limiting objective of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % rhenium, 35 wt% - 84 wt% tantalum (and all values and ranges therebetween), and one or more of a) 0.1 wt% - 25 wt% tungsten (and all values and ranges therebetween), b) 0.1 wt% - 55 wt% molybdenum (and all values and ranges therebetween), c) 0.01 wt% - 45 wt% niobium (and all values and ranges therebetween), d) 0.01 wt% - 5 wt% chromium (and all values and ranges therebetween), f) 0.01 wt% - 5 wt% titanium (and all values and ranges therebetween), g) 0.01 wt% - 5 wt% zirconium (and all values and ranges therebetween), and h) 0.01 wt% - 4 wt% hafnium (and all values and ranges therebetween).

[0188] Another and / or alternative non - limiting objective of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % rhenium, 40 wt% - 93 wt% molybdenum (and all values and ranges therebetween), and one or more of a) 0.1 wt% - 50 wt% tantalum (and all values and ranges therebetween), b) 0.1 wt% - 50 wt% tungsten (and all values and ranges therebetween), c) 0.01 wt% - 5 wt% hafnium (and all values and ranges therebetween), d) 0.01 wt% - 20 wt% chromium (and all values and ranges therebetween), e) 0.01 wt% - 3 wt% titanium (and all values and ranges therebetween), and f) 0.01 wt% - 2 wt% zirconium (and all values and ranges therebetween).

[0189] Another and / or alternative non - limiting objective of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % rhenium, 40 wt% - 85 wt% tungsten (and all values and ranges therebetween), and one or more of a) 0.01 wt% - 50 wt% molybdenum (and all values and ranges therebetween), b) 0.01 wt% - 50 wt% tantalum (and all values and ranges therebetween), d) 0.01 wt% - 5 wt% hafnium (and all values and ranges therebetween), d) 0.01 wt% - 50 wt% copper (and all values and ranges therebetween), e) 0.01 wt% - 8 wt% nickel (and all values and ranges therebetween), f) 0.01 wt% - 5 wt% iron (and all values and ranges therebetween), g) 0.01 wt% - 50 wt% zirconium (and all values and ranges therebetween), and h) 0.01 wt% - 20 wt% chromium (and all values and ranges therebetween).

[0190] Another and / or alternative non-limiting object of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % rhenium, 40 wt % - 85 wt % niobium (and all values and ranges therebetween), and one or more of a) 0.01 wt % - 20 wt % molybdenum (and all values and ranges therebetween), b) 0.01 wt % - 35 wt % tantalum (and all values and ranges therebetween), c) 0.01 wt % - 12 wt % hafnium (and all values and ranges therebetween), d) 0.01 wt % - 5 wt % zirconium (and all values and ranges therebetween), e) 0.01 wt % - 3 wt % titanium (and all values and ranges therebetween), f) 0.01 wt % - 15 wt % tungsten (and all values and ranges therebetween), and g) 0.01 wt % - 1 wt % yttrium (and all values and ranges therebetween).

[0191] Another and / or alternative non-limiting object of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % rhenium, 30 wt % - 58 wt % titanium (and all values and ranges therebetween), and 30 wt % - 58 wt % nickel (and all values and ranges therebetween).

[0192] Another and / or alternative non-limiting object of the present disclosure is to provide a metal alloy comprising at least 15 atomic weight % rhenium and one or more of a) 1 atomic weight % - 85 atomic weight % chromium (and all values and ranges therebetween), b) 0.1 atomic weight % - 10 atomic weight % titanium (and all values and ranges therebetween), c) 0.1 atomic weight % - 10 atomic weight % molybdenum (and all values and ranges therebetween), and d) 0.1 atomic weight % - 10 atomic weight % zirconium (and all values and ranges therebetween).

[0193] When considered in conjunction with the accompanying drawings, other objects, advantages, and novel features of the present invention will become apparent from the following detailed description of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0194] The following is a brief description of the drawings, which are provided to illustrate the exemplary embodiments disclosed herein and not to limit the same.

[0195] Figures 1-3 A comparison of the tensile strength, yield strength, and ductility of titanium alloys, cobalt-chromium alloys, and molybdenum-rhenium alloys is provided. DETAILED DESCRIPTION

[0196] Although specific terms are used in the following description for clarity, these terms are intended only to refer to the specific structures of the embodiments selected for illustration in the drawings and are not intended to limit or restrict the scope of the present disclosure. In the drawings and the following description, it should be understood that like reference numerals refer to components having the same function.

[0197] The singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

[0198] As used in the specification and claims, the term "comprising" can include embodiments "consisting of" and "consisting essentially of". As used herein, the terms "comprising", "including", "having", "has", "may", "containing", and variations thereof mean open transitional phrases, terms, or words that require the presence of the specified ingredient / step and allow the presence of other ingredients / steps. However, such description should also be construed as describing the composition or method as "consisting of the recited ingredients / steps" and "consisting essentially of the recited ingredients / steps", which allows only the presence of the specified ingredients / steps and any inevitable impurities that may result therefrom, and excludes other ingredients / steps.

[0199] The numerical values in the specification and claims of the present application should be understood to include the same numerical values when converted to the same number of significant figures, as well as numerical values that differ from the said values by less than the experimental error of the conventional measurement techniques used in the present application for determining that value.

[0200] All ranges disclosed herein include the endpoints and can be combined independently (e.g., the range "2 grams to 10 grams" includes the endpoints, 2 grams and 10 grams, and all intermediate values).

[0201] The terms "about" and "approximately" can be used to include any numerical value that can vary without changing the basic function of the value. When used with a range, "about" and "approximately" also disclose the range defined by the absolute values of the two endpoints. For example, "about 2 to about 4" also discloses the range "2 to 4". Generally, the terms "about" and "approximately" can refer to plus or minus 10% of the indicated number.

[0202] Now referring to Figures 1-3 , a comparison of the tensile strength, yield strength, and ductility of titanium alloys, cobalt-chromium alloys, and molybdenum-rhenium alloys is illustrated. The titanium alloy is a Ti-6Al-4V alloy. The cobalt-chromium alloy is an MP35N alloy. The molybdenum-rhenium alloy is a 50 wt% molybdenum and 50 wt% rhenium alloy. As Figures 1-3As shown, as titanium alloys and cobalt-chromium alloys are cold-worked and their cross-sectional area is reduced, the ductility of the two metal alloys decreases. However, as molybdenum-rhenium alloys are cold-worked and their cross-sectional area is reduced, the ductility of molybdenum-rhenium increases. This increase in ductility is observed in other metal alloys containing rhenium. This increase in the ductility of cold-worked metal alloys is referred to as the rhenium effect. When a metal alloy contains a sufficient amount of rhenium, it is found that the ductility of the rhenium-added metal alloy a) decreases at a significantly lower rate compared to a metal alloy that does not contain a sufficient amount of rhenium, or b) increases compared to the decrease in ductility when compared to a metal alloy that does not contain a sufficient amount of rhenium. The rhenium effect is observed in several metal alloys when the atomic weight of rhenium in the metal alloy is at least 15%.

[0203] Figures 1-3 It is also illustrated that the percentage increase in the yield strength and tensile strength of a molybdenum-rhenium alloy that has been cold-worked and has a reduced cross-sectional area is greater than the percentage increase in the yield strength and tensile strength of a titanium alloy and a cobalt-chromium alloy that have been similarly cold-worked and have a reduced cross-sectional area. After the molybdenum-rhenium alloy has been cold-worked and its cross-sectional area has been reduced by 50%, the yield tensile strength increases by approximately 33% (from 150 ksi to 200 ksi), and the yield strength increases by approximately 29% (from 175 ksi to 225 ksi). After the molybdenum-rhenium alloy has been cold-worked and its cross-sectional area has been reduced by 100%, the yield tensile strength increases by approximately 73% (from 150 ksi to 260 ksi), and the yield strength increases by approximately 71% (from 175 ksi to 300 ksi). The percentage increase in the tensile strength of molybdenum-rhenium is greater than the percentage increase in the tensile strength of a titanium alloy and a cobalt-chromium alloy that have been similarly cold-worked and have a reduced cross-sectional area.

[0204] Although the operations of the exemplary embodiments of the disclosed method may be described in a particular order for convenience of presentation, it should be understood that the disclosed embodiments may include an order of operations other than the particular order disclosed. For example, the operations described in order may in some cases be rearranged or performed simultaneously. In addition, the description and disclosure provided in connection with one particular embodiment are not limited to that embodiment and may be applied to any of the disclosed embodiments.

[0205] For simplicity, the drawings may not show the various ways in which the systems, methods, and devices disclosed herein may be combined with other systems, methods, and devices (which can be readily discerned by one of ordinary skill in the art based on the present disclosure). In addition, the specification sometimes uses terms such as "generate" and "provide" to describe the disclosed methods. These terms are abstractions of actual operations that can be performed. The actual operations corresponding to these terms may vary depending on the particular implementation and can be readily discerned by one of ordinary skill in the art based on the present disclosure.

[0206] Accordingly, it can be seen that the above objects, which are obvious from the foregoing description, are effectively achieved, and since certain changes may be made to the structures set forth without departing from the spirit and scope of the present disclosure, all matter contained in the above description and shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. The present disclosure has been described with reference to preferred and alternative embodiments. Modifications and variations will become apparent to those skilled in the art after a reading and understanding of the detailed discussion of the present disclosure provided herein. The present disclosure is intended to cover all such modifications and variations as fall within the scope of the present disclosure. It should also be understood that the following claims are intended to cover all general and specific features of the present disclosure described herein and all statements of the scope of the present disclosure, to the extent that such features and statements may be said to fall therebetween in language.

[0207] To assist the Patent Office and any readers of this application and any resulting patent in interpreting the appended claims, the applicant does not wish any of the appended claims or claim elements to be construed under 35 U.S.C. 112(f), unless the words "means for" or "step for" are expressly used in a particular claim.

Claims

1. A metal alloy comprising at least 15 atomic weight % of rhenium in the metal alloy; the metal alloy comprising one or more alloying metals selected from the group consisting of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, chromium, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, lithium, magnesium, manganese, molybdenum, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, zinc, and zirconium; the metal alloy a) having an increase in ductility of at least 10% compared to the metal alloy without rhenium, and / or b) having an increase in tensile strength of at least 10%.

2. The metal alloy according to claim 1, wherein the metal alloy comprises: I) at least 15 atomic weight % rhenium and 50 wt% - 78 wt% iron, and one or more of a) 9 wt% - 27 wt% chromium, b) 0.1 wt% - 26 wt% nickel, c) 0.01 wt% - 7 wt% molybdenum, d) 0.01 wt% - 16 wt% manganese, e) 0.01 wt% - 4 wt% silicon, f) 0.01 wt% - 2 wt% titanium, g) 0.01 wt% - 1 wt% selenium, h) 0.01 wt% - 1 wt% niobium, i) 0.01 wt% - 2 wt% aluminum, j) 0.01 wt% - 1 wt% tantalum, k) 0.01 wt% - 1 wt% cobalt, l) 0.01 wt% - 5 wt% copper, m) 0.01 wt% - 1 wt% vanadium, and n) 0.01 wt% - 2 wt% tungsten; or II) at least 15 atomic weight % rhenium and 35 wt% - 68 wt% cobalt, and one or more of a) 12 wt% - 28 wt% chromium, b) 0.01 wt% - 38 wt% nickel, c) 0.1 wt% - 30 wt% molybdenum, d) 0.01 wt% - 2 wt% manganese, e) 0.01 wt% - 1 wt% silicon, f) 0.01 wt% - 18 wt% tungsten, g) 0.01 wt% - 0.5 wt% lanthanum, h) 0.01 wt% - 20 wt% iron, i) 0.01 wt% - 5 wt% titanium, j) 0.01 wt% - 2 wt% niobium, k) 0.01 wt% - 2 wt% aluminum, l) 0.01 wt% - 1 wt% silicon, m) 0.01 wt% - 0.5 wt% boron, and n) 0.01 wt% - 0.5 wt% silver; or III) At least 15 atomic weight % rhenium and 70 wt% - 91.5 wt% titanium, and one or more of a) 2 wt% - 8 wt% aluminum, b) 0.01 wt% - 16 wt% vanadium, c) 0.01 wt% - 1 wt% iron, d) 0.01 wt% - 0.5 wt% yttrium, e) 0.01 wt% - 20 wt% chromium, f) 0.0 wt% - 16 wt% molybdenum, g) 0.01 wt% - 2 wt% nickel, h) 0.01 wt% - 12 wt% tin, i) 0.01 wt% - 6 wt% zirconium, j) 0.01 wt% - 2 wt% tantalum, k) 0.01 wt% - 4 wt% niobium, l) 0.01 wt% - 1 wt% silicon, and m) 0.01 wt% - 3 wt% iron; or IV) At least 15 atomic weight % rhenium, 35 wt% - 84 wt% tantalum, and one or more of a) 0.1 wt% - 25 wt% tungsten, b) 0.1 wt% - 55 wt% molybdenum, c) 0.01 wt% - 45 wt% niobium, d) 0.01 wt% - 5 wt% chromium, f) 0.01 wt% - 5 wt% titanium, g) 0.01 wt% - 5 wt% zirconium, and h) 0.01 wt% - 4 wt% hafnium; or V) At least 15 atomic weight % rhenium, 40 wt% - 93 wt% molybdenum, and one or more of a) 0.1 wt% - 50 wt% tantalum, b) 0.1 wt% - 50 wt% tungsten, c) 0.01 wt% - 5 wt% hafnium, d) 0.01 wt% - 20 wt% chromium, e) 0.01 wt% - 3 wt% titanium, and f) 0.01 wt% - 2 wt% zirconium; or VI) At least 15 atomic weight % rhenium, 40 wt% - 85 wt% tungsten, and one or more of a) 0.01 wt% - 50 wt% molybdenum, b) 0.01 wt% - 50 wt% tantalum, d) 0.01 wt% - 5 wt% hafnium, d) 0.01 wt% - 50 wt% copper, e) 0.01 wt% - 8 wt% nickel, f) 0.01 wt% - 5 wt% iron, g) 0.01 wt% - 50 wt% zirconium, and h) 0.01 wt% - 20 wt% chromium; or VII) At least 15 atomic weight % rhenium, 40 wt% - 85 wt% niobium, and one or more of a) 0.01 wt% - 20 wt% molybdenum, b) 0.01 wt% - 35 wt% tantalum, c) 0.01 wt% - 12 wt% hafnium, d) 0.01 wt% - 5 wt% zirconium, e) 0.01 wt% - 3 wt% titanium, f) 0.01 wt% - 15 wt% tungsten, and g) 0.01 wt% - 1 wt% yttrium; or VIII) At least 15 atomic weight % rhenium, 30 wt% - 58 wt% titanium, and 30 wt% - 58 wt% nickel; or IX) At least 15 atomic weight % of rhenium, and one or more of a) 1 atomic weight % - 85 atomic weight % of chromium, b) 0.1 atomic weight % - 10 atomic weight % of titanium, c) 0.1 atomic weight % - 10 atomic weight % of molybdenum, and d) 0.1 atomic weight % - 10 atomic weight % of zirconium; or X) At least 15 atomic weight % of rhenium, at least 10 atomic weight % of chromium, and at least 1 atomic weight % of molybdenum.

3. The metallic alloy according to claim 1, wherein the metallic alloy comprises at most 75 wt% of rhenium.

4. The metallic alloy according to claim 2, wherein the metallic alloy comprises at most 50 wt% of rhenium.

5. The metallic alloy according to claim 1, wherein the metallic alloy comprises less than 35 wt% of rhenium.

6. The metallic alloy according to claim 2, wherein the metallic alloy comprises less than 35 wt% of rhenium.

7. The metallic alloy according to claim 1, wherein the metallic alloy comprises less than 25 wt% of rhenium.

8. The metallic alloy according to claim 2, wherein the metallic alloy comprises less than 25 wt% of rhenium.

9. A medical device, which is partially or entirely formed of a metallic alloy; the metallic alloy comprises at least 15 atomic weight % of rhenium in an amount of the metallic alloy; the metallic alloy comprises one or more alloying metals selected from the group consisting of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, chromium, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, lithium, magnesium, manganese, molybdenum, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, zinc, and zirconium; the metallic alloy a) has an increased ductility of at least 10% compared to the metallic alloy without rhenium, and / or b) has an increased tensile strength of at least 10%.

10. The medical device according to claim 9, wherein the metallic alloy comprises: I) At least 15 atomic weight % of rhenium and 50 wt% - 78 wt% of iron, and one or more of a) 9 wt% - 27 wt% of chromium, b) 0.1 wt% - 26 wt% of nickel, c) 0.01 wt% - 7 wt% of molybdenum, d) 0.01 wt% - 16 wt% of manganese, e) 0.01 wt% - 4 wt% of silicon, f) 0.01 wt% - 2 wt% of titanium, g) 0.01 wt% - 1 wt% of selenium, h) 0.01 wt% - 1 wt% of niobium, i) 0.01 wt% - 2 wt% of aluminum, j) 0.01 wt% - 1 wt% of tantalum, k) 0.01 wt% - 1 wt% of cobalt, l) 0.01 wt% - 5 wt% of copper, m) 0.01 wt% - 1 wt% of vanadium, and n) 0.01 wt% - 2 wt% of tungsten; or II) At least 15 atomic weight % rhenium and 35 wt% - 68 wt% cobalt, and one or more of a) 12 wt% - 28 wt% chromium, b) 0.01 wt% - 38 wt% nickel, c) 0.1 wt% - 30 wt% molybdenum, d) 0.01 wt% - 2 wt% manganese, e) 0.01 wt% - 1 wt% silicon, f) 0.01 wt% - 18 wt% tungsten, g) 0.01 wt% - 0.5 wt% lanthanum, h) 0.01 wt% - 20 wt% iron, i) 0.01 wt% - 5 wt% titanium, j) 0.01 wt% - 2 wt% niobium, k) 0.01 wt% - 2 wt% aluminum, l) 0.01 wt% - 1 wt% silicon, m) 0.01 wt% - 0.5 wt% boron, and n) 0.01 wt% - 0.5 wt% silver; or III) At least 15 atomic weight % rhenium and 70 wt% - 91.5 wt% titanium, and one or more of a) 2 wt% - 8 wt% aluminum, b) 0.01 wt% - 16 wt% vanadium, c) 0.01 wt% - 1 wt% iron, d) 0.01 wt% - 0.5 wt% yttrium, e) 0.01 wt% - 20 wt% chromium, f) 0.0 wt% - 16 wt% molybdenum, g) 0.01 wt% - 2 wt% nickel, h) 0.01 wt% - 12 wt% tin, i) 0.01 wt% - 6 wt% zirconium, j) 0.01 wt% - 2 wt% tantalum, k) 0.01 wt% - 4 wt% niobium, l) 0.01 wt% - 1 wt% silicon, and m) 0.01 wt% - 3 wt% iron; or IV) At least 15 atomic weight % rhenium, 35 wt% - 84 wt% tantalum, and one or more of a) 0.1 wt% - 25 wt% tungsten, b) 0.1 wt% - 55 wt% molybdenum, c) 0.01 wt% - 45 wt% niobium, d) 0.01 wt% - 5 wt% chromium, f) 0.01 wt% - 5 wt% titanium, g) 0.01 wt% - 5 wt% zirconium, and h) 0.01 wt% - 4 wt% hafnium; or V) At least 15 atomic weight % rhenium, 40 wt% - 93 wt% molybdenum, and one or more of a) 0.1 wt% - 50 wt% tantalum, b) 0.1 wt% - 50 wt% tungsten, c) 0.01 wt% - 5 wt% hafnium, d) 0.01 wt% - 20 wt% chromium, e) 0.01 wt% - 3 wt% titanium, and f) 0.01 wt% - 2 wt% zirconium; or VI) At least 15 atomic weight % rhenium, 40 wt% - 85 wt% tungsten, and one or more of a) 0.01 wt% - 50 wt% molybdenum, b) 0.01 wt% - 50 wt% tantalum, d) 0.01 wt% - 5 wt% hafnium, d) 0.01 wt% - 50 wt% copper, e) 0.01 wt% - 8 wt% nickel, f) 0.01 wt% - 5 wt% iron, g) 0.01 wt% - 50 wt% zirconium, and h) 0.01 wt% - 20 wt% chromium; or VII) At least 15 atomic weight % rhenium, 40 wt% - 85 wt% niobium, and one or more of a) 0.01 wt% - 20 wt% molybdenum, b) 0.01 wt% - 35 wt% tantalum, c) 0.01 wt% - 12 wt% hafnium, d) 0.01 wt% - 5 wt% zirconium, e) 0.01 wt% - 3 wt% titanium, f) 0.01 wt% - 15 wt% tungsten, and g) 0.01 wt% - 1 wt% yttrium; or VIII) At least 15 atomic weight % rhenium, 30 wt% - 58 wt% titanium, and 30 wt% - 58 wt% nickel; or IX) At least 15 atomic weight % rhenium, and one or more of a) 1 atomic weight % - 85 atomic weight % chromium, b) 0.1 atomic weight % - 10 atomic weight % titanium, c) 0.1 atomic weight % - 10 atomic weight % molybdenum, and d) 0.1 atomic weight % - 10 atomic weight % zirconium; or X) At least 15 atomic weight % rhenium, at least 10 atomic weight % chromium, and at least 1 atomic weight % molybdenum.

11. The medical device according to claim 9, wherein the metal alloy comprises at most 75 wt% rhenium.

12. The medical device according to claim 10, wherein the metal alloy comprises at most more than 50 wt% rhenium.

13. The medical device according to claim 9, wherein the metal alloy comprises less than 35 wt% rhenium.

14. The medical device according to claim 10, wherein the metal alloy comprises less than 35 wt% rhenium.

15. The medical device according to claim 9, wherein the metal alloy comprises less than 25 wt% rhenium.

16. The medical device according to claim 10, wherein the metal alloy comprises less than 25 wt% rhenium.

17. The medical device according to claim 9, wherein at least one region of the medical device comprises at least one biologic agent.

18. The medical device according to any one of claims 10 to 16, wherein at least one region of the medical device comprises at least one biologic agent.

19. The medical device according to claim 9, wherein at least one region of the medical device comprises at least one polymer.

20. The medical device according to any one of claims 10 to 18, wherein at least one region of the medical device comprises at least one polymer.

21. The medical device according to claim 9, wherein at least one region of the medical device comprises at least one polymer, and the at least one polymer at least partially coats, encapsulates, or a combination thereof the at least one biologic.

22. The medical device according to any one of claims 10 to 20, wherein at least one region of the medical device comprises at least one polymer, and the at least one polymer at least partially coats, encapsulates, or a combination thereof the at least one biologic.

23. The medical device according to claim 9, wherein the medical device comprises an expandable frame formed of the metal alloy; the expandable frame comprises a plurality of struts; the expandable frame is configured to be crimped to a crimped state such that a maximum outer diameter of the expandable frame in the crimped state is less than a maximum outer diameter of the expandable frame when fully expanded to an expanded state; a) the expandable frame has a setback of less than 5% after undergoing a first crimping process; b) the expandable frame has a setback of less than 5% after expanding from the crimped state to the expanded state; c) the metal alloy has hydrophilicity, wherein a contact angle of a water droplet on a surface of the metal alloy is 25° - 45°; d) a maximum ion release of a main component of the metal alloy does not exceed 0.5 μg / cm 2 per day when the metal alloy is inserted or implanted on or into a patient's body, wherein the main component accounts for at least 2% by weight of the metal alloy; and / or e) an absolute increase in ion release of the metal alloy per dose in tissue around the medical device does not exceed 50 days after the metal alloy is inserted or implanted on or into a patient's body.

24. The medical device according to any one of claims 10 to 22, wherein the medical device comprises an expandable frame formed of the metal alloy; the expandable frame comprises a plurality of struts; the expandable frame is configured to be crimped to a crimped state such that the maximum outer diameter of the expandable frame in the crimped state is less than the maximum outer diameter of the expandable frame when fully expanded to an expanded state; a) the expandable frame has a springback of less than 5% after undergoing a first crimping process; b) the expandable frame has a springback of less than 5% after expanding from the crimped state to the expanded state; c) the metal alloy has hydrophilicity, wherein the contact angle of a water droplet on the surface of the metal alloy is 25° - 45°; d) the maximum ion release of the main component of the metal alloy does not exceed 0.5 μg / cm per day when the metal alloy is inserted or implanted on or into the patient's body; 2 , wherein the main component accounts for at least 2% by weight of the metal alloy; and / or e) the absolute increase in ion release of the metal alloy per dose in the tissue around the medical device does not exceed 50 days after the metal alloy is inserted or implanted on or into the patient's body.

25. A method for forming a metal alloy comprising at least 15 atomic weight % rhenium, comprising: a. Provide metal powder; The metal powder has i) an average particle size of 2 microns to 62 microns, ii) an average density greater than 5 g / cm3, and / or iii) a Hall flow rate (s / 50 g) of less than 30 seconds; the metal powder at least partially has at least 15 atomic weight % rhenium and a metal composition of one or more alloying metals selected from the group consisting of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, chromium, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lanthanum oxide, lead, lithium, magnesium, manganese, molybdenum, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, zinc, and zirconium; And b. Use 3D printing technology or direct metal printing technology to form the metal powder into a) a metal rod, b) a metal film, c) a metal sheet, d) a metal tube, e) a component of a medical device, or f) a medical device.

26. The method according to claim 25, wherein the metal powder comprises: I) at least 15 atomic weight % rhenium and 50% - 78% by weight iron, and a) 9% - 27% by weight chromium, b) 0.1% - 26% by weight nickel, c) 0.01% - 7% by weight molybdenum, d) 0.01% - 16% by weight manganese, e) 0.01% - 4% by weight silicon, f) 0.01% - 2% by weight titanium, g) 0.01% - 1% by weight selenium, h) 0.01% - 1% by weight niobium, i) 0.01% - 2% by weight aluminum, j) 0.01% - 1% by weight tantalum, k) 0.01% - 1% by weight cobalt, l) 0.01% - 5% by weight copper, m) 0.01% - 1% by weight vanadium, and n) 0.01% - 2% by weight tungsten, one or more of them; or II) at least 15 atomic weight % of rhenium and 35 wt% - 68 wt% of cobalt, and one or more of a) 12 wt% - 28 wt% of chromium, b) 0.01 wt% - 38 wt% of nickel, c) 0.1 wt% - 30 wt% of molybdenum, d) 0.01 wt% - 2 wt% of manganese, e) 0.01 wt% - 1 wt% of silicon, f) 0.01 wt% - 18 wt% of tungsten, g) 0.01 wt% - 0.5 wt% of lanthanum, h) 0.01 wt% - 20 wt% of iron, i) 0.01 wt% - 5 wt% of titanium, j) 0.01 wt% - 2 wt% of niobium, k) 0.01 wt% - 2 wt% of aluminum, l) 0.01 wt% - 1 wt% of silicon, m) 0.01 wt% - 0.5 wt% of boron and n) 0.01 wt% - 0.5 wt% of silver; or III) at least 15 atomic weight % of rhenium and 70 wt% - 91.5 wt% of titanium, and one or more of a) 2 wt% - 8 wt% of aluminum, b) 0.01 wt% - 16 wt% of vanadium, c) 0.01 wt% - 1 wt% of iron, d) 0.01 wt% - 0.5 wt% of yttrium, e) 0.01 wt% - 20 wt% of chromium, f) 0.0 wt% - 16 wt% of molybdenum, g) 0.01 wt% - 2 wt% of nickel, h) 0.01 wt% - 12 wt% of tin, i) 0.01 wt% - 6 wt% of zirconium, j) 0.01 wt% - 2 wt% of tantalum, k) 0.01 wt% - 4 wt% of niobium, l) 0.01 wt% - 1 wt% of silicon and m) 0.01 wt% - 3 wt% of iron; or IV) at least 15 atomic weight % of rhenium, 35 wt% - 84 wt% of tantalum, and one or more of a) 0.1 wt% - 25 wt% of tungsten, b) 0.1 wt% - 55 wt% of molybdenum, c) 0.01 wt% - 45 wt% of niobium, d) 0.01 wt% - 5 wt% of chromium, f) 0.01 wt% - 5 wt% of titanium, g) 0.01 wt% - 5 wt% of zirconium and h) 0.01 wt% - 4 wt% of hafnium; or V) at least 15 atomic weight % of rhenium, 40 wt% - 93 wt% of molybdenum, and one or more of a) 0.1 wt% - 50 wt% of tantalum, b) 0.1 wt% - 50 wt% of tungsten, c) 0.01 wt% - 5 wt% of hafnium, d) 0.01 wt% - 20 wt% of chromium, e) 0.01 wt% - 3 wt% of titanium and f) 0.01 wt% - 2 wt% of zirconium; or VI) At least 15 atomic weight % rhenium, 40 wt% - 85 wt% tungsten, and one or more of a) 0.01 wt% - 50 wt% molybdenum, b) 0.01 wt% - 50 wt% tantalum, d) 0.01 wt% - 5 wt% hafnium, d) 0.01 wt% - 50 wt% copper, e) 0.01 wt% - 8 wt% nickel, f) 0.01 wt% - 5 wt% iron, g) 0.01 wt% - 50 wt% zirconium, and h) 0.01 wt% - 20 wt% chromium; or VII) At least 15 atomic weight % rhenium, 40 wt% - 85 wt% niobium, and one or more of a) 0.01 wt% - 20 wt% molybdenum, b) 0.01 wt% - 35 wt% tantalum, c) 0.01 wt% - 12 wt% hafnium, d) 0.01 wt% - 5 wt% zirconium, e) 0.01 wt% - 3 wt% titanium, f) 0.01 wt% - 15 wt% tungsten, and g) 0.01 wt% - 1 wt% yttrium; or VIII) At least 15 atomic weight % rhenium, 30 wt% - 58 wt% titanium, and 30 wt% - 58 wt% nickel; or IX) At least 15 atomic weight % rhenium, and one or more of a) 1 atomic weight % - 85 atomic weight % chromium, b) 0.1 atomic weight % - 10 atomic weight % titanium, c) 0.1 atomic weight % - 10 atomic weight % molybdenum, and d) 0.1 atomic weight % - 10 atomic weight % zirconium; or X) At least 15 atomic weight % rhenium, at least 10 atomic weight % chromium, and at least 1 atomic weight % molybdenum.

27. The method according to claim 25, wherein at least 10% by volume of the metal powder is spherical.

28. The method according to claim 26, wherein at least 10% by volume of the metal powder is spherical.

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