Metal alloy with rhenium effect

Abstract

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

Description

[0001] This application is a divisional application of Chinese invention application No. 202380075491.3, entitled "Metal Alloy with Rhenium Effect", filed by Milus Ltd. (hereinafter referred to as the "parent application"). The parent application is PCT application PCT / US2023 / 029124, which entered into the national phase in China and claims priority 63 / 422,619, with a priority date of November 4, 2022.

[0002] This application claims priority to U.S. Provisional Application Serial No. 63 / 422,619, filed November 4, 2022, which is incorporated herein by reference.

[0003] This disclosure relates to rhenium-containing metal alloys, more specifically to metal alloys having a sufficient amount of rhenium to improve the ductility and tensile strength of the metal alloy, and even more specifically to metal alloys having a sufficient amount of rhenium to improve the ductility and tensile strength of the metal alloy, and such rhenium-containing metal alloys can be used to partially or wholly form medical devices. Background Technology

[0004] Standard stainless steel, standard cobalt-chromium alloys, and standard TiAlV alloys are some of the more common metallic alloys used in medical devices. Although these alloys have been successfully used to form a variety of medical devices, they have several drawbacks.

[0005] Many cardiovascular devices, such as stents and expandable heart valves, are inserted into a patient's vascular system and then expand at the treatment site. These devices are typically gripped onto a catheter before insertion. The minimum diameter at which a cardiovascular device can be gripped onto a catheter limits the size of the cardiovascular pathway (e.g., blood vessel) into which the device can be inserted. A smaller gripping diameter reduces the risk of injury to blood vessels and / or organs (e.g., the heart) during insertion and / or placement at the treatment site. A smaller gripping diameter also allows the device to be placed in smaller diameter blood vessels (e.g., blood vessels in the brain).

[0006] The gripping diameter of an expandable cardiovascular device can be reduced by decreasing the thickness and / or size of the frame, struts, etc. However, such reduction in size also affects the strength of the cardiovascular device after expansion. After expansion, the cardiovascular device must maintain its expanded shape in the treatment area; otherwise, the cardiovascular device may shift from the treatment area, potentially damage the treatment area, and / or fail to function properly in the treatment area. Therefore, cardiovascular devices made of conventional 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 the grip diameter can be obtained by the gripping cardiovascular device. Other types of standard cobalt-chromium alloys already in use 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 and 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).

[0007] Furthermore, conventional materials such as standard stainless steel (316L) and standard cobalt-chromium alloys (e.g., MP35N, etc.) exhibit a degree of springback after gripping and expansion, which may hinder achieving the minimum gripping diameter and / or potentially adversely affect the placement of expandable cardiovascular devices in the treatment area. During the gripping process, the gripping device is typically used to grip the cardiovascular device onto the catheter. After the initial gripping process, conventional materials such as stainless steel and cobalt-chromium alloys spring back to a larger diameter, approximately 9+% of the minimum gripping diameter. Therefore, the cardiovascular device must be gripped onto the catheter multiple times in an attempt to achieve a smaller gripping diameter on the catheter. However, subjecting the cardiovascular device to repeated gripping can lead to 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 expands in the treatment area, conventional materials of the cardiovascular device will spring back to 9+% of the maximum expansion diameter. Therefore, the expandable balloon on the catheter must be inflated multiple times to repeatedly expand the cardiovascular device in the treatment area, thereby ensuring proper expansion of the cardiovascular device. However, subjecting cardiovascular devices to repeated balloon dilation may result in damage to the cardiovascular device (e.g., damage or rupture of the frame and / or struts) and / or damage to the treatment area (e.g., rupture of blood vessels, tearing of organs and / or perforation).

[0008] Given the current state of the medical device field, there is a need for an improved medical device that a) produces less springback compared to medical devices made of standard stainless steel, standard cobalt-chromium alloy, or standard TiAlV alloy, and b) can form a smaller gripping diameter compared to medical devices made of standard stainless steel, standard cobalt-chromium alloy, or standard TiAlV alloy. Summary of the Invention

[0009] This disclosure relates to rhenium-containing metal alloys, more specifically to metal alloys having a sufficient amount of rhenium to improve the ductility and tensile strength of the metal alloy, and even more specifically to metal alloys having a sufficient amount of rhenium to improve the ductility and tensile strength of the metal alloy, and such rhenium-containing metal alloys can be used to partially or wholly form medical devices.

[0010] In one non-limiting aspect of this disclosure, a medical device is provided that is at least partially made of a rhenium-containing metal alloy. The medical device may include orthopedic devices, PFO (patent foramen ovale) devices, stents, valves (e.g., heart valves, TAVR valves, mitral valve replacements, tricuspid valve replacements, pulmonary valve replacements, etc.), spinal implants, frames and other structures used with spinal implants, vascular implants, grafts, guidewires, sheaths, catheters, needles, stent catheters, electrophysiological catheters, hypotubes, nails, cutting devices, implants of any type, pacemakers, dental implants, dental crowns, orthodontic appliances, wires used in medical procedures, bone implants, artificial intervertebral discs, artificial spinal discs, and devices for repairing, replacing, and / or supporting bones (e.g., acromion, atlas, axis, calcaneus, carpal bones, clavicle, coccyx). Prosthetic implants or devices of bones, epicondyles, medial epicondyle of the humerus, femur, fibula, frontal bone, greater trochanter, humerus, ilium, ischium, mandible, maxilla, metacarpals, metatarsals, occipital bone, olecranon, parietal bone, patella, phalanges, radius, ribs, sacrum, scapula, sternum, talus, tarsal bones, temporal bone, tibia, ulna, zygomatic bone, etc.) and / or cartilage; bone plates, screws, rods, screws, columns, cages, plates, pedicle screws, caps, hinges, joint systems, anchors, washers, shafts, anchors, discs, balls, tension bands, locking connectors; and 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, animal, etc.). In one non-limiting embodiment, the medical device includes an expandable frame (e.g., stent, artificial heart valve, etc.) that can be radially and plastically deformed 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 of 10%-100% (and all values ​​and ranges therebetween) of a metal alloy containing a sufficient amount of rhenium to produce a "rhenium effect" within the metal alloy. In another non-limiting embodiment, the medical device is formed of 50%-100% of a metal alloy containing a sufficient amount of rhenium to produce a "rhenium effect" within the metal alloy.

[0011] According to another and / or alternative aspect of this 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, a "rhenium effect" is a) an increase in the ductility of a metal alloy by at least 10% by adding rhenium to the metal alloy, and / or b) an increase in the tensile strength of a 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 steel, 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 the addition of rhenium to a metal alloy can lead to the formation of twinned alloys in the metal alloy, which results in an increase in the overall ductility of the metal alloy with increasing yield strength and tensile strength, the increase of which is due to reduction and / or work hardening of the metal alloy containing the added rhenium. The rhenium effect occurs when the atomic weight of rhenium in a metallic alloy is at least 15% (e.g., 15-99 atomic weight rhenium and all values ​​and ranges therebetween). For example, for standard stainless steel alloys, the rhenium effect can begin when the stainless steel alloy is modified to include at least 5-10 wt% (and all values ​​and ranges therebetween) of rhenium. For standard CoCr alloys, the rhenium effect can begin when the CoCr alloy is modified to include at least 4.8-9.5 wt% (and all values ​​and ranges therebetween) of rhenium. For standard TiAlV alloys, the rhenium effect can begin when the TiAlV alloy is modified to include at least 4.5-9 wt% (and all values ​​and ranges therebetween) of rhenium. It is understood that the rhenium content in the above examples may be greater than the minimum amount required to produce the rhenium effect in a metallic alloy.

[0012] According to another and / or alternative aspect of this disclosure, the metal alloy comprises at least 15 atomic weight percent rhenium and at least 0.1 wt percent (e.g., from 0.1 wt percent to 96 wt percent and all values ​​and ranges therein) one or more of the following metals: aluminum, bismuth, chromium, cobalt, copper, hafnium, iridium, iron, magnesium, manganese, molybdenum, nickel, niobium, osmium, rhodium, ruthenium, silicon, silver, tantalum, technetium, titanium, tungsten, vanadium, yttrium, and zirconium.

[0013] According to another and / or alternative aspect of this 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 refractory metal alloy. As defined herein, a refractory metal alloy is a metal alloy containing at least 20% by weight of one or more of molybdenum, rhenium, niobium, tantalum, or tungsten. Non-limiting metal 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.

[0014] According to another and / or alternative aspect of this 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 stainless steel alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, the standard stainless steel alloy contains 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% selenium, 0 wt%–2 wt% vanadium, 0 wt%–2 wt% tungsten, and at least 50 wt% iron. Standard 316L alloy contains 17-19 wt% chromium, 13-15 wt% nickel, 2-4 wt% molybdenum, up to 2 wt% manganese, up to 0.75 wt% silicon, up to 0.03 wt% carbon, and the balance iron.

[0015] According to another and / or alternative aspect of this 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 cobalt-chromium alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, the 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, and 30 wt%–68 wt% cobalt. The standard MP35N alloy contains 19-21 wt% chromium, 34-36 wt% nickel, 9-11 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. The standard Phynox and standard Elgiloy alloys contain 38-42 wt% cobalt, 18-22 wt% chromium, 14-18 wt% iron, 13-17 wt% nickel, and 6-8 wt% molybdenum. The standard L605 alloy contains 18-22 wt% chromium, 14-16 wt% tungsten, 9-11 wt% nickel, and the balance cobalt.

[0016] According to another and / or alternative aspect of this 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 TiAlV alloy that has been modified to contain at least 15 atomic weight percent rhenium. The 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, and 0 wt%–0.2 wt% carbon. The 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, with the balance being titanium.

[0017] According to another and / or alternative aspect of this 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.

[0018] According to another and / or alternative aspect of this 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, and 0 wt%–3 wt% silicon.

[0019] According to another and / or alternative aspect of this 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, 0.05 wt% cobalt, and 0 wt%–2 wt% iron.

[0020] According to another and / or alternative aspect of this 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, and 0 wt%–4 wt% iron.

[0021] According to another and / or alternative aspect of this 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, and 0 wt%–2 wt% lanthanum.

[0022] According to another and / or alternative aspect of this 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, and 0 wt%–20 wt% nickel.

[0023] According to another and / or alternative aspect of this 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.

[0024] According to another and / or alternative aspect of this 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 beryllium-copper alloy that has been modified to contain at least 15 atomic weight percent rhenium. As defined herein, a standard beryllium-copper alloy contains 95 wt%–98.5 wt% copper, 1 wt%–4 wt% beryllium, 0 wt%–1 wt% cobalt, and 0 wt%–0.5 wt% silicon.

[0025] Several non-limiting examples of metal alloys that can be used to partially or wholly form the frame of a medical device are illustrated below in weight percentage:

[0026] In Examples 1-210, it should be understood that all the above ranges include the range itself and any value between any other ranges between the above ranges. Any of the above values ​​including the ≤ sign includes the range from 0 to the specified value and all values ​​and ranges in between.

[0027] According to another and / or alternative aspect of this disclosure, the metal alloy comprises at least 15 atomic weight percent (e.g., 10 atomic weight percent to 99 atomic weight percent and all values ​​and ranges therebetween) rhenium. In a non-limiting embodiment, the metal alloy comprises at least 15 atomic weight percent (e.g., 15 atomic weight percent to 99.9 atomic weight percent and all values ​​and ranges therebetween) rhenium and 0.1 wt% to 95.5 wt% (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 percent (e.g., 20 atomic weight percent to 99.9 atomic weight percent and all values ​​and ranges therebetween) of rhenium and 0.1 wt percent to 94 wt percent (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 wt percent to 2 wt percent (and all values ​​and ranges therebetween) of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen and nitrogen.

[0028] According to another and / or alternative aspect of this disclosure, the metal alloy comprises 35% to 75% by weight (e.g., and all values ​​and ranges therein) of a metal alloy containing rhenium, and 25% to 65% by weight (and all values ​​and ranges therein) of a metal alloy containing 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% to 2% by weight of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen and nitrogen in combination with other combinations. In one non-limiting embodiment, the metal alloy comprises 50%-75% rhenium, 24%-49% chromium, 1%-15% molybdenum, and 0%-25% 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%-2% of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen.

[0029] According to another and / or alternative aspect of this 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% to 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% to 15 wt%, and the metal alloy comprises 0 wt% to 2 wt% of other metals, carbon, oxygen and nitrogen combinations.

[0030] According to another and / or alternative aspect of this 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 formulation, the metal alloy comprises rhenium and molybdenum, and the weight percentage of molybdenum in the metal alloy is at least 10% by weight and less than 50% by weight (and all values ​​and ranges therebetween) and 0% to 25% by weight (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% to 2% by weight of other metals, carbon, oxygen and nitrogen combinations. In another non-limiting specific formulation, the metal alloy contains rhenium at a weight percentage of 41 wt% to 58.5 wt% (and all values ​​and ranges therebetween), molybdenum at a weight percentage of at least 15 wt% to 45 wt% (and all values ​​and ranges therebetween), and a combination of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper and iridium at a weight percentage of 11 wt% to 41 wt% (and all values ​​and ranges therebetween). In another non-limiting specific formulation, the metal alloy contains rhenium at a weight percentage of 41 wt% to 58.5 wt% (and all values ​​and ranges therebetween), molybdenum at a weight percentage of at least 15 wt% to 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% to 41 wt% (and all values ​​and ranges therebetween). In another non-limiting specific formulation, the metal alloy contains rhenium at a weight percentage of 41 wt% to 58.5 wt% (and all values ​​and ranges therebetween), molybdenum at a weight percentage of at least 15 wt% to 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% to 41 wt% (and all values ​​and ranges therebetween).In another non-limiting embodiment of the 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 yet another non-limiting specific 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.

[0031] According to another and / or alternative aspect of this disclosure, the metal alloy comprises rhenium and molybdenum, and the atomic weight percentage of rhenium is in the ratio of the atomic weight percentage of bismuth, niobium, tantalum, tungsten, titanium, vanadium, chromium, manganese, yttrium, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper and iridium to a ratio of 0.7:1 to 1.5:1 (and all values ​​and ranges therebetween), typically 0.8:1 to 1.4:1, more typically 0.8:1 to 1.25:1, and even more typically about 0.9:1 to 1.1:1 (e.g., 1:1). In one specific non-limiting formulation, the metal alloy comprises rhenium and molybdenum, and the atomic weight percentage of rhenium is in the ratio of the atomic weight percentage of bismuth, chromium, iridium, niobium, tantalum, titanium, yttrium, and zirconium to the atomic weight percentage of the combination of bismuth, chromium, iridium, niobium, tantalum, titanium, yttrium, and zirconium in a ratio of 0.7:1 to 5.1:1 (and all values ​​and ranges therebetween), typically 0.8:1 to 1.5:1, more typically 0.8:1 to 1.25:1, and even more typically 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 atomic weight percentage of rhenium is in the ratio of the atomic weight percentage of chromium, niobium, tantalum, and zirconium to the atomic weight percentage of the combination of chromium, niobium, tantalum, and zirconium in a ratio of 0.7:1 to 5.1:1 (and all values ​​and ranges therebetween), typically 0.8:1 to 1.5:1, more typically 0.8:1 to 1.25:1, and even more typically about 0.9:1 to 1.1:1 (e.g., 1:1).

[0032] According to another and / or alternative aspect of this 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, the atomic ratio of the two additional metals being from 0.4:1 to 2.5:1 (and all values ​​and ranges therebetween), and typically from 0.5:1 to 2:1. In a 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 being 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 percent rhenium and two of chromium, niobium, tantalum, and zirconium, with the atomic ratio of the two metals being 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.

[0033] According to another and / or alternative aspect of this disclosure, the metal alloy is formed of at least 15 atomic weight percent 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 the metal alloy containing other elements and compounds is 0 wt% to 0.1 wt%, typically 0 wt% to 0.01 wt%, and more typically 0 wt% to 0.001 wt%. In another specific non-limiting formulation, the metal alloy is formed of at least 15 atomic weight percent rhenium plus at least three metals selected from the group consisting of molybdenum, chromium, niobium, tantalum, and zirconium, and the content of the metal alloy containing other elements and compounds is 0 wt% to 0.1 wt%, typically 0 wt% to 0.01 wt%, and more typically 0 wt% to 0.001 wt%. In another non-limiting embodiment, the metal alloy comprises rhenium, molybdenum, and chromium.

[0034] According to another and / or alternative aspect of this disclosure, the metal alloy comprises at least 35 wt% (e.g., 35 wt% to 75 wt% and all values ​​and ranges therebetween) rhenium, and the metal alloy also 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% to 49.9 wt% and all values ​​and ranges therebetween) chromium. In another non-limiting embodiment, the metal alloy comprises at least 35 wt% rhenium and at least 30 wt% chromium. In yet another non-limiting embodiment, the metal alloy comprises at least 35 wt% rhenium and at least 33 wt% chromium. In another non-limiting embodiment, at least 50% by weight (e.g., 50% to 74.9% by weight and all values ​​and ranges therein) of the metal alloy contains rhenium, at least 25% by weight (e.g., 25% to 49.9% by weight and all values ​​and ranges therein) of the metal alloy contains chromium, and 0.1% to 25% by weight (and all values ​​and ranges therein) of the metal alloy contains 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% by weight (e.g., 50% to 74.9% by weight and all values ​​and ranges therein) of the metal alloy contains rhenium, at least 25% by weight (e.g., 25% to 49.9% by weight and all values ​​and ranges therein) of the metal alloy contains chromium, and 0.1% to 25% by weight (and all values ​​and ranges therein) of the metal alloy contains 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 contains 0-2% by weight of other metals, carbon, oxygen and nitrogen combinations. In another non-limiting embodiment, at least 55 wt% (e.g., 55 wt% to 69.9 wt% and all values ​​and ranges therein) of the metal alloy contains rhenium, at least 30 wt% (e.g., 30 wt% to 44.9 wt% and all values ​​and ranges therein) of the metal alloy contains chromium, and 0.1 wt% to 15 wt% (and all values ​​and ranges therein) of the metal alloy contains 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 contains 0 wt% to 2 wt% of other metals, carbon, oxygen and nitrogen combinations.

[0035] According to another and / or alternative aspect of this disclosure, the metal alloy comprises 15 atomic weight percent to 60 atomic weight percent of 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 percent to 60 atomic weight percent of rhenium and one or more metals selected from the group consisting of 0.5 atomic weight percent to 70 atomic weight percent of chromium (and all values ​​and ranges therebetween), 0.5 atomic weight percent to 70 atomic weight percent of tantalum (and all values ​​and ranges therebetween), 0.5 atomic weight percent to 70 atomic weight percent of niobium (and all values ​​and ranges therebetween), 0.5 atomic weight percent to 70 atomic weight percent of titanium (and all values ​​and ranges therebetween), 0.5-70 atomic weight percent of zirconium (and all values ​​and ranges therebetween), and 0.5 atomic weight percent to 70 atomic weight percent of molybdenum (and all values ​​and ranges therebetween).

[0036] According to another and / or alternative aspect of this 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).

[0037] According to another and / or alternative aspect of this 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).

[0038] According to another and / or alternative aspect of this 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).

[0039] According to another and / or alternative aspect of this 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).

[0040] According to another and / or alternative aspect of this 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).

[0041] According to another and / or alternative aspect of this 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).

[0042] According to another and / or alternative aspect of this disclosure, the metal alloy comprises at least 15 atomic weight percent rhenium, greater than 50 wt percent titanium (e.g., 51 wt percent to 80 wt percent and all values ​​and ranges therebetween), 15 wt percent to 45 wt percent niobium (and all values ​​and ranges therebetween), 1 wt percent to 10 wt percent zirconium (and all values ​​and ranges therebetween), and 1 wt percent to 15 wt percent tantalum (and all values ​​and ranges therebetween). In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight percent rhenium, 58 wt percent to 70 wt percent titanium, 27 wt percent to 37 wt percent niobium, 2 wt percent to 9 wt percent zirconium, and 1 wt percent to 15 wt percent tantalum.

[0043] According to another and / or alternative aspect of this disclosure, the metal alloy comprises at least 15 atomic weight percent rhenium, greater than 50 wt percent titanium (e.g., 51 wt percent to 80 wt percent and all values ​​and ranges therebetween), 15 wt percent to 45 wt percent niobium (and all values ​​and ranges therebetween), and 1 wt percent to 10 wt percent molybdenum (and all values ​​and ranges therebetween). In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight percent rhenium, 58 wt percent to 69 wt percent titanium, 27 wt percent to 33 wt percent niobium, and 4 wt percent to 8 wt percent molybdenum.

[0044] According to another and / or alternative aspect of this disclosure, the metal alloy comprises at least 15 atomic weight % rhenium, 30 to 60 wt% cobalt (and all values ​​and ranges therebetween), 10 to 30 wt% chromium (and all values ​​and ranges therebetween), 5 to 20 wt% iron (and all values ​​and ranges therebetween), 5 to 22 wt% nickel (and all values ​​and ranges therebetween), and 2 to 12 wt% molybdenum (and all values ​​and ranges therebetween). In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight % rhenium, 35 to 45 wt% cobalt, 15 to 25 wt% chromium, 12 to 20 wt% iron, 10 to 20 wt% nickel, and 5 to 9 wt% molybdenum.

[0045] According to another and / or alternative aspect of this disclosure, the metal alloy comprises at least 15 atomic weight % rhenium, 30 to 60 wt% zirconium (and all values ​​and ranges therebetween), and 30 to 60 wt% molybdenum (and all values ​​and ranges therebetween). In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight % rhenium, 35 to 55 wt% cobalt, and 35 to 55 wt% molybdenum.

[0046] According to another and / or alternative aspect of this disclosure, the metal alloy comprises at least 15 atomic weight % rhenium, 80 wt% to 95 wt% niobium (and all values ​​and ranges therebetween), and 0.5 wt% to 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% to 95 wt% niobium, and 0.75 wt% to 4 wt% niobium.

[0047] According to another and / or alternative aspect of this disclosure, the metal alloy comprises at least 15 atomic weight percent rhenium, 55 to 75 wt percent niobium (and all values ​​and ranges therebetween), 18 to 40 wt percent tantalum (and all values ​​and ranges therebetween), 1 to 7 wt percent tungsten (and all values ​​and ranges therebetween), and 0.5 to 4 wt percent zirconium (and all values ​​and ranges therebetween). In a non-limiting formulation, the metal alloy comprises at least 15 atomic weight percent rhenium, 60 to 70 wt percent niobium, 24 to 32 wt percent tantalum, 2 to 5 wt percent tungsten, and 0.75 to 3 wt percent zirconium.

[0048] According to another and / or alternative aspect of this disclosure, a metal alloy optionally used to partially or completely form a medical device comprises 38 wt% to 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% to 30 wt% additive metal (and all values ​​and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 70 wt% to 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% to 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 the additive material in the metal alloy is optionally from 0.8:1 to 1.25:1 (and all values ​​and ranges therebetween).

[0049] According to another and / or alternative aspect of this disclosure, a metal alloy optionally used to partially or completely form a medical device comprises 40 wt% to 55 wt% rhenium (and all values ​​and ranges therebetween), 30 wt% to 46 wt% molybdenum (and all values ​​and ranges therebetween), and 12 wt% to 20 wt% additive metal (and all values ​​and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 80 wt% to 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% to 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 the additive material in the metal alloy is optionally from 0.8:1 to 1.25:1 (and all values ​​and ranges therebetween).

[0050] According to another and / or alternative aspect of this disclosure, a metal alloy optionally used to partially or completely form a medical device comprises 38 wt% to 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% to 30 wt% additive metal (and all values ​​and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 70 wt% to 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% to 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 the additive material in the metal alloy is optionally from 0.8:1 to 1.25:1. (and all values ​​and ranges in between).

[0051] According to another and / or alternative aspect of this disclosure, a metal alloy optionally used to partially or completely form a medical device comprises 40 wt% to 55 wt% rhenium (and all values ​​and ranges therebetween), 30 wt% to 46 wt% molybdenum (and all values ​​and ranges therebetween), and 12 wt% to 20 wt% additive metal (and all values ​​and ranges therebetween); wherein the combined content of rhenium and molybdenum accounts for 80 wt% to 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% to 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 the additive material in the metal alloy is optionally from 0.8:1 to 1.25:1 (and all values ​​and ranges therebetween).

[0052] According to another and / or alternative aspect of this disclosure, a metal alloy optionally used to partially or completely form a medical device comprises 38 wt% to 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% to 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% to 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 the additive material in the metal alloy is optionally from 0.8:1 to 1.25:1.

[0053] According to another and / or alternative aspect of this disclosure, a metal alloy optionally used to partially or completely form a medical device comprises 38 wt% to 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% to 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% to 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 the additive material in the metal alloy is optionally from 0.8:1 to 1.25:1 (and all values ​​and ranges therebetween).

[0054] According to another and / or alternative aspect of this disclosure, a metal alloy optionally used to partially or completely form a medical device comprises 38 wt% to 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% to 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% to 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 rhenium to the total content of the additive material in the metal alloy is optionally from 0.8:1 to 1.25:1 (and all values ​​and ranges therebetween).

[0055] According to another and / or alternative aspect of this disclosure, at least 30% by weight (e.g., 30% to 100% by weight and all values ​​and ranges therein) of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic weights of rhenium. In another non-limiting embodiment, at least 40% by weight of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten. In another non-limiting embodiment, at least 50% by weight of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic weights of rhenium.

[0056] According to another and / or alternative aspect of this disclosure, at least 50% by weight (e.g., 50% to 100% by weight and all values ​​and ranges therein) of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum or tungsten, and the metal alloy comprises at least 15 atomic weights of rhenium, and 0% to 40% by weight (and all values ​​and ranges therein) 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% by weight (e.g., 50% to 99.9% by weight and all values ​​and ranges therein) of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic weights of rhenium, and 0.1% to 40% by weight (and all values ​​and ranges therein) 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% by weight (e.g., 50% to 100% by weight and all values ​​and ranges therein) of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic weights of rhenium, and 0% to 40% by weight (and all values ​​and ranges therein) 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% to 2% by weight (and all values ​​and ranges therein) of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen. In another non-limiting embodiment, at least 50% by weight (e.g., 50% to 99.9% by weight and all values ​​and ranges therein) of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic weights of rhenium, and 0.1% to 40% by weight (and all values ​​and ranges therein) 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% to 2% by weight (and all values ​​and ranges therein) of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen.In another non-limiting embodiment, at least 55% by weight of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic weight of rhenium, and 0% to 40% by weight 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% to 0.1% by weight of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen. In another non-limiting embodiment, at least 55% by weight of the metal alloy comprises one or more of molybdenum, niobium, rhenium, tantalum, or tungsten, and the metal alloy comprises at least 15 atomic weight of rhenium, and 0.1% to 40% by weight 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% to 0.1% by weight of other metals, carbon, oxygen, phosphorus, sulfur, hydrogen, and nitrogen.

[0057] According to another and / or alternative aspect of this disclosure, the metal alloy comprises at least 30% by weight (e.g., 30% to 99% by weight and all values ​​and ranges therein) 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% to 99 wt% and all values ​​and ranges therebetween) one or more of rhenium and 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% to 2 wt% (and all values ​​and ranges therebetween) of other metals, carbon, oxygen, and nitrogen. In another non-limiting embodiment, the metal alloy comprises at least 30% by weight (e.g., 30-99% by weight and all values ​​and ranges therein) one or more of rhenium and 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% by weight (and all values ​​and ranges therein) of other metals, carbon, oxygen, and nitrogen. In another non-limiting embodiment, the metal alloy comprises at least 35 wt% (e.g., 35 wt% to 99 wt% and all values ​​and ranges therein) rhenium and 0.1 wt% to 65 wt% (and all values ​​and ranges therein) 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% to 99 wt% and all values ​​and ranges therein) of rhenium and 0.1 wt% to 65 wt% (and all values ​​and ranges therein) 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% to 2 wt% (and all values ​​and ranges therein) 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 therein) of rhenium and 0.1-65 wt% (and all values ​​and ranges therein) 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 therein) of other metals, carbon, oxygen, and nitrogen. In another non-limiting embodiment, the metal alloy comprises at least 40% by weight (e.g., 40-99.9% by weight and all values ​​and ranges therein) rhenium and 0.1-60% by weight (and all values ​​and ranges therein) 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 therein) rhenium and 0.1-60 wt% (and all values ​​and ranges therein) 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 therein) of other metals, carbon, oxygen, and nitrogen combinations. In another non-limiting embodiment, the metal alloy comprises at least 40 wt% (e.g., 40-99.9 wt% and all values ​​and ranges therein) rhenium and 0.1-60 wt% (and all values ​​and ranges therein) 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 therein) of other metals, carbon, oxygen, and nitrogen.

[0058] According to another and / or alternative aspect of this disclosure, a metal alloy is provided, wherein at least 20 wt% (e.g., 20 wt% to 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% to 99.9 wt% and all values ​​and ranges therebetween) rhenium and 0.1 wt% to 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% to 99.9 wt% and all values ​​and ranges therein) rhenium and 0.1 wt% to 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% by weight (e.g., 30-99.9% by weight and all values ​​and ranges therein) rhenium and 0.1-70% by weight 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% to 99.9 wt% and all values ​​and ranges therein) of rhenium and 0.1 wt% to 70 wt% (and all values ​​and ranges therein) of one or more of copper, chromium, hafnium, iridium, manganese, molybdenum, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, zirconium and / or such components. In another non-limiting embodiment, the metal alloy comprises at least 35% by weight (e.g., 35-99.9% by weight and all values ​​and ranges therein) rhenium and 0.1-65% by weight 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% to 99.9 wt% and all values ​​and ranges therein) of rhenium and 0.1 wt% to 65 wt% (and all values ​​and ranges therein) of one or more of copper, chromium, hafnium, iridium, manganese, molybdenum, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, zirconium and / or such components. In another non-limiting embodiment, the metal alloy comprises 35% to 60% by weight (and all values ​​and ranges therebetween) rhenium and 40% to 65% by weight 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 these components. In another non-limiting embodiment, the metal alloy comprises 35 wt% to 60 wt% (and all values ​​and ranges therebetween) rhenium and 40 wt% to 65 wt% (and all values ​​and ranges therebetween) copper, chromium, hafnium, iridium, manganese, molybdenum, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, zirconium and / or alloys of one or more of these components. In another non-limiting embodiment, the metal alloy comprises at least 40% by weight (e.g., 40-99.9% by weight and all values ​​and ranges therein) rhenium and 0.1-60% by weight 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 40 wt% (e.g., 40-99.9 wt% and all values ​​and ranges therein) rhenium and 0.1-60 wt% (and all values ​​and ranges therein) of one or more of copper, chromium, hafnium, iridium, manganese, molybdenum, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, zirconium and / or such components. In one non-limiting embodiment, the metal alloy comprises at least 50 wt% (e.g., 50 wt% to 99.9 wt% and all values ​​and ranges therein) rhenium and 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 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% to 99.9 wt% and all values ​​and ranges therein) of rhenium and 0.1 wt% to 50 wt% (and all values ​​and ranges therein) of one or more of copper, chromium, hafnium, iridium, manganese, molybdenum, niobium, osmium, rhodium, ruthenium, tantalum, technetium, titanium, tungsten, vanadium, zirconium and / or such components.

[0059] According to another and / or alternative aspect of this disclosure, the metal used to form 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, one or more of such components, 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.). 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, rubber, laminates, nonwoven materials, etc. In one non-limiting formulation, the metal alloy comprises at least 15 atomic weight percent rhenium and at most 40 wt percent rhenium and at least 60 wt percent tungsten. In one non-limiting embodiment, the total weight percentage of tungsten and rhenium in the tungsten-rhenium alloy is at least about 95 wt%, typically at least about 99 wt%, more typically at least about 99.5 wt%, still more typically at least about 99.9 wt%, and even more typically at least about 99.99 wt%. In another non-limiting formulation, the metal alloy comprises at least 15 atomic weight percent rhenium and at most 47.5 wt percent rhenium and at least 20 wt percent to 80 wt percent tungsten (and all values ​​and ranges therebetween) and 1 wt percent to 47.5 wt percent molybdenum (and all values ​​and ranges therebetween). In a tungsten-rhenium-molybdenum alloy, the total weight percentage of tungsten, rhenium, and molybdenum is at least about 95% by weight, typically at least about 99% by weight, more typically at least about 99.5% by weight, still more typically at least about 99.9% by weight, and even more typically at least about 99.99% by weight. 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% by weight of the tungsten-rhenium-molybdenum alloy. In yet 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 yet 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.

[0060] According to another and / or alternative aspect of this disclosure, a metal alloy is provided wherein at least 30 wt% (e.g., 30 wt% to 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 yet another non-limiting embodiment, at least 35 wt% (e.g., 35 wt% to 99.9 wt% and all values ​​and ranges therebetween) of the metal alloy comprises rhenium, and 0.1 wt% to 65 wt% (and all values ​​and ranges therebetween) of the metal alloy comprises one or more of molybdenum, niobium, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and / or iridium. In another non-limiting embodiment, 35% to 60% by weight (and all values ​​and ranges therewith) of the metal alloy comprises rhenium, and 40% to 65% by weight (and all values ​​and ranges therewith) 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% to 60% by weight (e.g., and all values ​​and ranges therewith) of the metal alloy comprises rhenium, and 40% to 65% by weight (and all values ​​and ranges therewith) of the metal alloy comprises two or more of molybdenum, niobium, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, and / or iridium. In another non-limiting embodiment, 35% to 60% by weight (e.g., and all values ​​and ranges therein) of the metal alloy contains rhenium, and 40% to 65% by weight (and all values ​​and ranges therein) of the metal alloy contains three or more of molybdenum, niobium, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper and / or iridium.

[0061] According to another and / or alternative aspect of this disclosure, the metal used to form the metal alloy comprises at least 35 wt% rhenium (e.g., 35 wt% to 99.9 wt% and all values ​​and ranges therebetween) and one or more alloying agents, such as, but not limited to, molybdenum, niobium, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper and / or iridium, and / or alloys of one or more of such components. In one non-limiting formulation, the metal alloy comprises 40 wt% to 99.9 wt% rhenium and one or more molybdenum, niobium, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper and / or iridium. In another non-limiting formulation, the metal alloy comprises rhenium and one or more molybdenum, niobium, tantalum, titanium, vanadium, chromium, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper and / or iridium.

[0062] According to another and / or alternative aspect of this disclosure, the metal used to form the metal alloy comprises at least 15 atomic weight percent rhenium, molybdenum, and one or more alloy 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 the alloy metal 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 the alloy metal 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% to 60 wt% (and all values ​​and ranges therebetween). In another non-limiting embodiment, the combined weight percentage of the alloy metal is 5 wt% to 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 the alloy metals. In another non-limiting embodiment, the combined weight percentage of rhenium, molybdenum, and one or more alloy metals in the metal alloy is at least 99.9% by weight. In another non-limiting embodiment, the alloy metal includes chromium. In another non-limiting embodiment, the alloy metal includes 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 alloy metal includes 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 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 alloy metal includes chromium and one or more metals selected from the group consisting of zirconium, niobium, and tantalum. In another non-limiting embodiment, the alloy 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; 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 alloy 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; 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).

[0063] According to another and / or alternative aspect of this disclosure, at least 35 wt% (e.g., 35 wt% to 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% to 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 yet 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% to 74.9 wt% and all values ​​and ranges therein) of the metal alloy contains rhenium, at least 25 wt% (e.g., 25 wt% to 49.9 wt% and all values ​​and ranges therein) of the metal alloy contains chromium, and 0.1 wt% to 25 wt% (and all values ​​and ranges therein) of the metal alloy contains 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% to 69.9 wt% and all values ​​and ranges therein) of the metal alloy contains rhenium, at least 30 wt% (e.g., 30 wt% to 44.9 wt% and all values ​​and ranges therein) of the metal alloy contains chromium, and 0.1 wt% to 15 wt% (and all values ​​and ranges therein) of the metal alloy contains 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% to 69.9 wt% and all values ​​and ranges therein) of the metal alloy contains rhenium, at least 30 wt% (e.g., 30 wt% to 39.9 wt% and all values ​​and ranges therein) of the metal alloy contains chromium, and 0.1 wt% to 10 wt% (and all values ​​and ranges therein) of the metal alloy contains 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% to 67.9 wt% and all values ​​and ranges therein) of the metal alloy contains rhenium, at least 32 wt% (e.g., 32 wt% to 32.9 wt% and all values ​​and ranges therein) of the metal alloy contains chromium, and 0.1 wt% to 6 wt% (and all values ​​and ranges therein) of the metal alloy contains one or more of molybdenum, bismuth, niobium, tantalum, titanium, vanadium, tungsten, manganese, zirconium, technetium, ruthenium, rhodium, hafnium, osmium, copper, yttrium, zirconium and / or iridium.

[0064] According to another and / or alternative aspect of this disclosure, the metal alloy optionally contains less than about 5% by weight (e.g., 0% to 4.999999% by weight and all values ​​and ranges therebetween) of other metals and / or impurities, typically 0% to 1% by weight, more typically 0% to 0.1% by weight, even more typically 0% to 0.01% by weight, and even more typically 0% to 0.001% by weight. The high purity level of the metal alloy results in the formation of a more homogeneous 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 a 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 metal alloy containing other elements and compounds is present in a content of 0% to 0.1% by weight, typically 0% to 0.01% by weight, and more typically 0% to 0.001% by weight.

[0065] According to another and / or alternative aspect of this disclosure, a medical device (e.g., a stent, an artificial heart valve, etc.) is provided, which is at least partially formed of a metal alloy and configured to radially contract to a contracted or compressible state for introduction into the body via a delivery catheter and radially expandable to an expanded state for implantation of an artificial heart valve into a desired location in the body (e.g., a blood vessel, heart, ureter, bile duct, pancreatic duct, esophagus, lung, eye, sinus, oral stent, etc.). The frame of the medical device may be formed of a malleably expandable material that allows the frame to be compressed into a smaller profile for delivery and expansion of the medical device using an expansion device (such as a balloon in a balloon catheter).

[0066] According to another and / or alternative aspect of this disclosure, a medical device is provided comprising a frame optionally coated with a polymeric material (e.g., silicone, PTFE, ePTFE, polyurethane, polyolefin, hydrogel, biomaterial (e.g., pericardium or biopolymers such as collagen, gelatin, or hyaluronic acid derivatives)). The coating may be used to partially or completely encapsulate the struts on the frame and / or fill the openings between the struts.

[0067] According to another and / or alternative aspect of this disclosure, the metal alloy used to form at least a portion of a medical device has one or more improved properties (e.g., strength, durability, hardness, biocompatibility, flexural properties, coefficient of friction, radial strength, flexibility, tensile strength, elongation at break, longitudinal elongation, stress-strain characteristics, reduced springback, radiation impermeability, thermal sensitivity, biocompatibility, improved fatigue life, crack resistance, crack propagation 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 reactions, reduced metal ion release, reduced corrosion, reduced allergic reactions, improved hydrophilicity, reduced toxicity, reduced metal component thickness, improved bone fusion, and / or reduced ion release from tissue. These improved physical properties of metal alloys can be achieved in medical devices without increasing the size, volume and / or weight of the medical device, and in some cases, these improved physical properties can be obtained even when the size, volume and / or weight of the medical device is reduced compared to a medical device made at least partially of standard stainless steel, standard titanium alloy or standard cobalt and chromium alloy materials.

[0068] Therefore, metal alloys used to at least partially form medical devices can 1) increase the radiation impermeability 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 gripping and / or expansion characteristics of the medical device, 6) improve the bending 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 springback characteristics of the medical device, 10) improve the biocompatibility and / or biostability 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 gripping medical devices, and 15) improve the medical device when used and / or expanded in the treatment area. 16) Improve the consistency of the shape of the device with the treatment area; 17) Reduce the rebound of the device with respect to the shape of the treatment area when the device expands in the treatment area; 18) Increase the yield strength of the device; 19) Improve the fatigue ductility of the device; 20) Improve the durability of the device; 21) Improve the fatigue life of the device; 22) Reduce adverse tissue reactions after implantation; 23) Reduce the release of metal ions after implantation; 24) Reduce the corrosion of the device after implantation; 25) Reduce allergic reactions after implantation; 26) Improve the hydrophilicity of the device; 27) Reduce the thickness of the metal components of the device; 28) Improve bone fusion with the device; 29) Reduce the release of ions from the device into the tissue; 20) Reduce the magnetization of the device when implanted in the patient; and / or 20) Reduce the toxicity of the device after implantation.

[0069] Medical devices may optionally undergo one or more manufacturing processes. These manufacturing processes may include, but are not limited to, expansion, laser cutting, etching, pressing, annealing, drawing, pilgering, electroplating, electropolishing, machining, plasma coating, 3D printing coating, chemical vapor deposition, chemical polishing, cleaning, pickling, ion beam deposition or implantation, sputtering coating, vacuum deposition, etc.

[0070] According to another and / or alternative aspect of this disclosure, the metal alloy optionally contains a certain amount of carbon and oxygen; however, this is not required. Both elements have been found to affect the forming properties and brittleness of the metal alloy. The controlled atomic ratio of carbon to oxygen in the metal alloy also minimizes the tendency for the metal alloy to form microcracks during at least partial formation of the metal alloy into a medical device and / or during the use and / or expansion of the medical device in vivo. Control of the carbon-to-oxygen atomic ratio in the metal alloy allows for the redistribution of oxygen within the metal alloy to minimize the tendency for microcracks in the metal alloy during at least partial formation of the metal alloy into a medical device and / or during the use and / or expansion of the medical device in vivo. It is believed that the carbon-to-oxygen atomic ratio in the metal alloy contributes to minimizing the tendency for microcracks in the metal alloy and increasing the elongation of the metal alloy, both of which can affect one or more physical properties of the metal alloy that are useful or desirable during the formation and / or use of the medical device. The carbon-to-oxygen atomic ratio 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 metal alloy is typically at least about 0.3:1. Typically, the carbon content of the metal alloy is less than about 0.1 wt% (e.g., 0 wt% to 0.0999999 wt% and all values ​​and ranges therebetween), and more typically 0 wt% to 0.01 wt%. Excessive carbon content can adversely affect the physical properties of the metal alloy. Typically, the oxygen content is kept at very low levels. In a non-limiting formulation, the oxygen content is less than about 0.1 wt% of the metal alloy (e.g., 0 wt% to 0.0999999 wt% and all values ​​and ranges therebetween), and typically 0 wt% to 0.01 wt%. It is believed that when the oxygen content in the metal alloy exceeds a certain amount, by strictly controlling the carbon to oxygen ratio, the metal alloy has a very low tendency to form microcracks during the formation of the medical device and after the medical device is inserted into the patient. In a non-limiting arrangement, when the oxygen content in the metal alloy is greater than about 100 ppm, the atomic ratio of carbon to oxygen in the metal alloy is at least about 2.5:1.

[0071] According to another and / or alternative aspect of this disclosure, the metal alloy optionally contains a controlled amount of nitrogen; however, this is not required. A high nitrogen content in a metal alloy can adversely affect its ductility. This, in turn, can adversely affect the elongation properties of the metal alloy. Excessively high nitrogen content in a metal alloy may begin to cause an unacceptably reduced ductility, thereby adversely affecting one or more physical properties of the metal alloy that are useful or desirable in the formation and / or use of medical devices. In a non-limiting formulation, the metal alloy contains less than about 0.001% by weight of nitrogen (e.g., 0% by weight to 0.0009999% by weight and all values ​​and ranges therebetween). It is believed that the nitrogen content in the metal alloy should be lower than the carbon or oxygen content. In a 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 therein).

[0072] According to another and / or alternative aspect of this disclosure, the medical device is generally designed to comprise at least about 5% by weight of a metal alloy (e.g., 5% to 100% by weight and all values ​​and ranges therebetween). In one non-limiting embodiment of this disclosure, the medical device comprises at least about 50% by weight of a metal alloy. In another non-limiting embodiment of this disclosure, the medical device comprises at least about 95% by weight of a metal alloy. In a particular construction, when the medical device includes an expandable frame, the expandable frame is formed of 50% to 100% by weight (and all values ​​and ranges therebetween) of a metal alloy, and typically 75% to 100% by weight of a metal alloy.

[0073] In yet another and / or alternative non-limiting aspect of the invention, the novel metal alloy used to form all or part of a medical device 1) is not coated, metal-sprayed, electroplated, and / or formed (e.g., cold-worked, hot-worked, etc.) onto another metal, or 2) does not have another metal or metal alloy metal-sprayed, electroplated, coated, and / or formed onto the novel metal alloy. It should be understood that in some applications, when forming all or part of a medical device, the novel metal alloy of the invention may be coated, metal-sprayed, electroplated, and / or formed onto another metal, or another metal or metal alloy may be electroplated, metal-sprayed, coated, and / or formed onto the novel metal alloy.

[0074] In another and / or alternative non-limiting aspect of the invention, the novel alloy can be used to form a) a coating on a portion of a complete medical device, or b) a portion or all of the core of a medical device. In one non-limiting embodiment, the novel alloy can be used as a coating on the joint points of an artificial joint. This coating provides the beneficial effects of improved wear resistance, scratch resistance, and / or elimination of the leaching of harmful metal ions (i.e., Co, Cr, etc.) from the joint surface when the joint surface is subjected to micro-vibration wear (i.e., scratching during relative movement). It is understood that the novel alloy may 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, braces, etc.). The composition of the novel alloy coating differs 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 therein). 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 ceramic or composite material, and another layer of the coated rod is formed of a novel alloy. The core and the other layer may each form 10%-99% of the total cross-section of the rod (and all values ​​and ranges therebetween). The novel alloy coating may be used to form a hard surface at specific locations and across the entire surface of the medical device. The base hardness of the novel alloy may 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, this disclosure includes a method that can provide the beneficial effects of a softer metal alloy with 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 machinability. Simultaneously, the finished screw requires a hard shell. When using the new alloy, the internal hardness can range from 250 Vickers hardness to 550 Vickers hardness (and all values ​​and ranges in between), while the external hardness can vary from 350 Vickers hardness to 1000 Vickers hardness (and all values ​​and ranges in between). Understandably, other internal and external hardness values ​​may be used for medical devices.

[0075] In another non-limiting embodiment, the medical device may be in the form of a rod. The core of the rod may be formed of a novel alloy, and the exterior of the core may be coated with one or more other materials (e.g., another type of metal or 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.), polymer coating, ceramic coating, composite material coating, etc.). Such a rod can 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 novel alloys 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 is understood that the novel alloy may have other or additional advantages. It is also understood that the novel alloy may be formed into the core of other or additional types of medical devices. The core size and / or thickness of the novel alloy are non-limiting. 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 novel alloy, and another layer covering the rod is formed of a different metallic composition (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 and the other layer may each form 10%–99% of the total cross-section of the rod (and all values ​​and ranges therebetween). It is also understood that the novel alloy may be used to form the core of other or additional types of medical devices.

[0076] According to another and / or alternative aspect of this 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.

[0077] According to another and / or alternative aspect of this disclosure, when the medical device is at least partially formed of a metallic alloy of this disclosure, the metallic alloy possesses several physical properties that positively influence the medical device. In one non-limiting embodiment of this disclosure, the average Vickers hardness of the metallic alloy used to at least partially form the medical device is optionally at least about 150 Vickers hardness (e.g., 150 Vickers hardness to 300 Vickers hardness and all values ​​and ranges therebetween), and typically 160 Vickers hardness to 240 Vickers hardness; however, this is not required. The metallic alloy of this disclosure typically has an average hardness greater than that of standard stainless steel. In another and / or alternative non-limiting embodiment of this disclosure, the average ultimate tensile strength of the metallic alloy of this disclosure is optionally at least about 125 ksi (e.g., 125 ksi to 300 ksi and all values ​​and ranges therebetween); however, this is not required. In another and / or alternative non-limiting embodiment of this disclosure, the average yield strength of the metal alloy of this disclosure is optionally at least about 100 ksi (e.g., 100 ksi to 275 ksi and all values ​​and ranges therein); however, this is not required. In another and / or alternative non-limiting embodiment of this disclosure, the average grain size of the metal alloy of this 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 therein, e.g., 0.35 micrometers to 90 micrometers and all values ​​and ranges therein). The small grain size of the metal alloy of this disclosure enables the medical device to have the desired elongation and ductility, which can be used to enable the medical device to be formed, gripped, and / or expanded.

[0078] In another and / or alternative non-limiting embodiment of this disclosure, the average tensile elongation of the metal alloy used to at least partially form the 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% in the metal alloy facilitates proper expansion of the medical device when positioned in a treatment area of ​​the body. Medical devices without an average tensile elongation of at least about 25% may be more prone to microcrack formation and / or fracture during the formation, gripping, and / or expansion of the medical device. The unique combination of metals in the metal alloy of this disclosure, combined with the desired alloy purity and composition, as well as the desired grain size of the metal alloy, results in: 1) a medical device with the desired high ductility at approximately room temperature; 2) a medical device with the desired tensile elongation; 3) a homogeneous or solid solution of a metal alloy with high radiometric impermeability; 4) reduced or prevented microcrack formation and / or fracture of the metal alloy of the tube of this disclosure when the tube is sized and / or cut to form the medical device; 5) reduced or prevented microcrack formation and / or fracture of the medical device when the device is gripped; and 6) reduced... Or prevent microcrack formation and / or fracture of the medical device, 7) medical devices with desired ultimate tensile strength and yield strength, 8) medical devices with very thin wall thickness and still having the desired radial force required to keep the medical device in the open state when expanded, 9) medical devices exhibiting less springback when the medical device is pressed onto a delivery system and / or expanded in vivo, 10) medical devices exhibiting improved conformity to the shape of the treatment area in vivo when the medical device expands in vivo, 11) medical devices exhibiting improved fatigue ductility, and / or 12) medical devices exhibiting improved durability.

[0079] According to another and / or alternative aspect of this disclosure, the metal alloy is optionally formed at least partially by a forging process; however, this is not required. In a non-limiting embodiment, the metal alloy is forged to at least partially or completely achieve the final dimensions of one or more portions of the medical device. The forging die may be shaped to fit the final dimensions of the medical device; however, this is not required. In the case of an undercut with a hollow structure in the medical device (which is not required), a separate metal sheet may be placed in the undercut to at least partially fill the gap. The separate metal sheet (when used) may be designed to be removed from the undercut later; however, this is not required. The forging operation may be performed on the area of ​​the medical device to be hardened. For circular or curved portions of the medical device, the forging may be rotary. For non-circular portions of the medical device, the forging of the non-circular portions of the medical device may be performed using a non-rotating forging die. Instead of rotation or in addition to rotation, the die may optionally be made to vibrate in the radial and / or longitudinal directions. The medical device may optionally be forged in a single operation or multiple operations in multiple directions to achieve hardness at a desired location and / or direction of the medical device. The forging temperature for a particular metal alloy can be varied. For a metal alloy, if forging is performed in air or an oxidizing environment, the forging temperature can be from room temperature (RT) (e.g., 10°C–27°C and all values ​​and ranges therebetween) to approximately 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 up to approximately 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 location to be hardened at the desired forging temperature. In a non-limiting embodiment, during the forging process, boron and / or nitrogen ions are allowed to bombard rhenium atoms in a rhenium-containing metal alloy to form ReB2, ReN2, and / or ReN3; however, this is not necessary. ReB2, ReN2, and / or ReN3 have been found to be superhard compounds. In a non-limiting method, a metal for a medical device can be processed and formed into a medical device while the metal is in a less hardened state. Therefore, the raw material can first be annealed to soften it, and then the metal can be processed into the desired shape. After the metal alloy is formed, it can be re-hardened. The hardening of the metal alloy in 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, thus requiring a special re-hardening process. This re-hardening can be achieved through the forging process of this disclosure.

[0080] According to another and / or alternative aspect of this disclosure, the metal alloy may optionally be nitrided; however, this is not required. When partially or completely forming a medical device, the nitrided layer on the metal alloy can act as a lubricating surface during the optional drawing of the metal alloy. After nitriding, the metal alloy is typically cleaned; however, this is not required. 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 to the surface of the metal alloy, thereby producing a nitrided layer. The thickness and phase composition of the resulting nitrided layer can be selected, and the process can be optimized for specific desired characteristics. 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 may optionally be used to clean oxide layers and / or solvents 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 nitride surface layer is at least about 50 nanometers and less than about 0.1 mm. Typically, the weight percentage of nitrogen in the nitride surface layer is 0.0001 wt% to 5 wt% nitrogen (and all values ​​and ranges therebetween). In one non-limiting embodiment, the weight percentage of nitrogen in the nitride surface layer is typically less than one of the major components of the metal alloy, and typically less than each of the two major components of the metal alloy. For example, when a metal alloy is nitrided, the weight percentage of nitrogen in the nitride surface layer is less than the weight percentage of rhenium in the nitride surface layer. In a non-limiting composition of a nitrided surface layer on a 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 comprises 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 metal alloys can be used to increase the surface hardness and / or wear resistance of medical devices, and / or to 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 wear parts on joint surfaces or metal alloys used in medical devices to extend the life of the medical device, and / or increase the wear life of mating surfaces on medical devices (e.g., polyethylene linings of joint implants such as knee, hip, shoulder, etc.), and / or reduce particulate matter generated by the use of the medical device, and / or maintain the appearance of the metal alloy on the outer surface of the medical device.

[0081] According to another and / or alternative aspect of this disclosure, the metal alloy may optionally be cleaned, polished, sterilized, nitrided, etc., just before or after it is partially or completely formed into the desired medical device, for the final processing of the metal alloy. In one non-limiting embodiment of this disclosure, the metal alloy is electropolished. In one non-limiting aspect of this embodiment, the metal alloy is cleaned before exposure to a polishing solution; however, this is not required.

[0082] According to another and / or alternative aspect of this disclosure, the medical device may optionally include and / or be coated with one or more agents that promote the success of the medical device and / or the treatment area. The term "agent" includes, but is not limited to, substances, pharmaceuticals, biological products, veterinary products, medicines, and analogues or derivatives 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 conditions; digestive diseases and / or conditions; reproductive diseases and / or conditions; lymphatic diseases and / or conditions; cancer; graft rejection; pain; nausea; swelling; arthritis; bone diseases and / or conditions; organ failure; immune diseases and / or conditions; cholesterol problems; blood diseases and / or conditions; lung diseases and / or conditions; heart diseases and / or conditions; brain diseases and / or conditions; neuralgia diseases and / or conditions; kidney diseases and / or conditions; Ulcers, liver diseases and / or conditions, intestinal diseases and / or conditions, gallbladder diseases and / or conditions, pancreatic diseases and / or conditions, mental disorders, respiratory diseases and / or conditions, glandular diseases and / or conditions, skin diseases and / or conditions, hearing diseases and / or conditions, oral diseases and / or conditions, nasal diseases and / or conditions, eye diseases and / or conditions, fatigue, genetic diseases and / or conditions, burns, scars and / or blemishes, trauma, weight disorders and / or conditions, addiction disorders and / or conditions, hair loss, painful spasms, muscle spasms, tissue repair, nerve repair, nerve regeneration, etc. The type and / or amount of the agent contained in and / or applied to the medical device may vary. When two or more agents are contained in and / or applied to the medical device, the amounts of the two or more agents may be the same or different. One or more agents may be coated onto and / or impregnated in a medical device via a variety of mechanisms, including but not limited to spraying (e.g., atomization spraying techniques), flame spraying, powder deposition, dip coating, flow coating, dip-spin coating, roll coating (direct and reverse), ultrasonic treatment, brush coating, plasma deposition, deposition via vapor deposition, MEMS techniques, and rotary die deposition. In another and / or alternative non-limiting embodiment of this disclosure, the type and / or amount of agents typically selected to be contained on, in, and / or combined with the medical device for treating one or more medical therapies. The amounts of two or more agents used on, in, and / or combined with the medical device may be the same or different. When used on and / or in the medical device, one or more agents may optionally be released in a controlled manner to provide the desired dose of agent to the area to be treated over a sustained period of time. It is understood that controlled release of one or more agents on the medical device is not always necessary and / or desirable.Therefore, during and / or after insertion of the medical device into the treatment area, one or more agents on and / or in the medical device may be uncontrollably released from the medical device. It is also understood that one or more agents on and / or in the medical device may be controllably released from the medical device, and one or more agents on and / or in the medical device may be uncontrollably released from the medical device. It is also understood that one or more agents on and / or in one area of ​​the medical device may be controllably released from the medical device, and one or more agents on and / or in the medical device may be uncontrollably released from another area of ​​the medical device. Therefore, the medical device may be designed such that: 1) all agents on and / or in the medical device are controllably released, 2) some agents on and / or in the medical device are controllably released, and some agents on the medical device are uncontrollably released, or 3) all agents on and / or in the medical device are uncontrollably released. The medical device may also be designed such that one or more agents are released from the medical device at the same or different rates. Medical devices can also be designed such that one or more agents are released at the same or different rates from one or more regions of the medical device. Non-limiting arrangements that can be used to control the release of one or more agents from a medical device include 1) coating one or more agents at least partially with one or more polymers, 2) incorporating one or more agents at least partially into one or more polymers and / or encapsulating one or more agents at least partially into one or more polymers and / or encapsulating them with one or more polymers, and / or 3) inserting one or more agents into orifices, channels, cavities, etc., in the medical device and coating or covering such orifices, channels, cavities, etc., at least partially with one or more polymers. It is understood that other or additional means may be used to control the release of one or more agents from a medical device. When used to at least partially control the release of one or more agents from a medical device, the one or more polymers may be porous or non-porous. One or more agents may be inserted into and / or applied to 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. Therefore, one or more agents on a medical device may 1) be coated on one or more surface areas of the medical device, 2) be inserted into and / or impregnated in one or more surface structures and / or microstructures of the medical device, and / or 3) form at least a portion of the structure of the medical device or be contained in at least a portion of the structure of the medical device.When one or more agents are applied to a medical device, the agents may 1) be applied directly to 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 applied to one or more surfaces of the medical device, 3) be at least partially applied to the surface of another coating material that has already been at least partially applied to the medical device, and / or 4) be at least partially encapsulated between a) a surface or area 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 may be used additionally or alternatively. When one or more agents are optionally inserted into 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 may 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 may be combined with one or more agents. Therefore, one or more agents may 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 a base structure and a polymer coating, 5) be mixed in the base structure of a medical device including at least one polymer coating, or 6) one or more combinations of 1, 2, 3, 4 and / or 5. Alternatively or additionally, one or more coatings of one or more polymers on the medical device may include 1) one or more coatings of a nonporous polymer, 2) one or more coatings of a combination of one or more porous polymers and one or more nonporous polymers, 3) one or more coatings of a porous polymer, or 4) one or more combinations of options 1, 2 and 3.

[0083] In another and / or alternative aspect of this disclosure, different agents may optionally be located in and / or between different polymer coatings 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 dosage of one or more agents; however, other or additional combinations may be used. Therefore, the combination of agents and polymer systems, and their location 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 prior to 1) controlled release of one or more agents through one or more layers of a polymer system comprising one or more nonporous polymers, and / or 2) uncontrolled release of one or more agents through one or more layers of the polymer system. One or more pharmaceutical agents and / or polymers can be coated onto medical devices through a variety of mechanisms, such as, but not limited to, spraying (e.g., atomized spraying technology), dip coating, roll coating, ultrasonic treatment, brush coating, plasma deposition and / or deposition via vapor deposition.

[0084] In another and / or alternative aspect of this disclosure, various polymers may optionally be coated on and / or used to form at least a portion of the medical device. One or more polymers may be used on the medical device for a variety of reasons, including but not limited to 1) forming a portion 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 on 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 the medical device. One or more polymers may be porous, non-porous, biostable, biodegradable (i.e., dissolve, degrade, absorb, or any combination thereof in vivo), and / or biocompatible. When a medical device is coated with one or more polymers, the polymers may include 1) one or more coatings of a nonporous polymer, 2) one or more coatings of a combination of one or more porous polymers and one or more nonporous polymers, 3) one or more coatings of one or more porous polymers and one or more coatings of one or more nonporous 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 the medical device, the one or more coatings may be applied using a variety of techniques, such as, but not limited to, vapor deposition and / or plasma deposition, spraying, dip coating, roll coating, ultrasonic treatment, atomization, brushing, etc.; however, other or additional coating techniques may be used. The one or more polymers that can be coated onto the medical device and / or used to at least partially form the medical device may be polymers considered to be biodegradable, bioresorbable, or bioerectable; polymers considered to be biostable; and / or polymers that can be modified to be biodegradable and / or bioresorbable. 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 to 75 µm, more particularly about 0.05 µm to 50 µm, and even more particularly about 1 µm to 30 µm. It is understood that other thicknesses may be used.

[0085] According to another and / or alternative aspect of this disclosure, when a medical device includes and / or is coated with one or more pharmaceutical agents, the medical device may include and / or may be coated with one or more pharmaceutical 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 biological products on at least a portion of the medical device, and at least another portion of the medical device is not coated with and / or contains pharmaceutical agents; 2) be coated with and / or contain one or more biological products that are different from the one or more biological products on at least another portion of the medical device; and / or 3) be coated with and / or contain one or more biological agents at a concentration different from the concentration of the one or more biological agents on at least another portion of the medical device.

[0086] According to another and / or alternative aspect of this disclosure, one or more portions of the medical device may optionally 1) contain the same or different pharmaceutical agents, 2) contain the same or different amounts of one or more pharmaceutical agents, 3) contain the same or different polymer coatings, 4) contain one or more polymer coatings of the same or different coating thicknesses, 5) enable one or more portions of the medical device to controllably release and / or uncontrollably release one or more pharmaceutical agents, and / or 6) enable one or more portions of the medical device to controllably release one or more pharmaceutical agents and enable one or more portions of the medical device to uncontrollably release one or more pharmaceutical agents.

[0087] According to another and / or alternative aspect of this disclosure, one or more surfaces of the medical device may optionally be treated to achieve desired coating properties of one or more pharmaceutical agents and one or more polymers applied to 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.), etc. It is understood that other or additional surface treatment methods may be used prior to applying one or more pharmaceutical agents and / or polymers to the surface of the medical device.

[0088] In another and / or alternative non-limiting aspect of this disclosure, the medical device may optionally include a marking material that facilitates proper positioning of the medical device within a body passage. The marking material is typically designed to be visible to electromagnetic waves (e.g., X-rays, microwaves, visible light, infrared waves, ultraviolet light, etc.); acoustic waves (e.g., ultrasound, 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 marking material may form all or part of the medical device and / or be coated on one or more parts of the medical device (flared portions and / or body portions, at the ends of the medical device, at or near the transition between the body portion and the flared portion, etc.). The marking material may be located at one or more locations on the medical device. The one or more areas containing the marking material may be the same or different in size. The marking materials may be spaced apart from each other at a defined distance to form ruler-shaped marks on the medical device, thereby facilitating positioning of the medical device within a body passage. The marking material may be a rigid or flexible material. The marking material may be a biostable or biodegradable material.

[0089] According to another and / or alternative aspect of this disclosure, a medical device or one or more regions thereof may optionally be constructed using one or more microelectromechanical manufacturing (MEMS) techniques (e.g., micromachining, laser micromachining, micromolding, etc.); however, other or additional manufacturing techniques may be used.

[0090] According to another and / or alternative aspect of this disclosure, the medical device may optionally include one or more surface structures (e.g., holes, channels, pits, ribs, grooves, notches, ridges, teeth, needles, holes, cavities, recesses, etc.). These structures may be formed at least in part by MEMS (e.g., microfabrication, etc.) techniques and / or other types of techniques.

[0091] According to another and / or alternative aspect of this disclosure, the medical device may optionally include one or more microstructures (e.g., microneedles, micropores, microcylinders, microcones, micropyramids, microtubes, microparallelograms, microprisms, microhemispheres, teeth, ribs, spines, ratchet wheels, hinges, zippers, zipper-like structures, etc.) on its surface. 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.) not exceeding about 2 mm and generally not exceeding about 1 mm. It is understood that when the medical device includes one or more surface structures, 1) all surface structures may be microstructures, 2) all surface structures may be non-microstructures, or 3) a portion of the surface structure may be microstructures and a portion may be non-microstructures. Typically, microstructures (when formed) extend from or into the outer surface of no more than about 400 micrometers (0.01 micrometers to 400 micrometers and all values ​​and ranges in between), and more typically less than about 300 micrometers, and more typically about 15 to 250 micrometers; however, other sizes may be used. Microstructures may aggregate together or be distributed across the entire surface of the medical device. Microstructures and / or surface structures of similar shapes and / or sizes 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, one or more surface structures and / or microstructures may be formed in the extension location and / or designed to extend from the medical device during and / or after the medical device is deployed in the treatment area. Microstructures and / or surface structures may be designed to include and / or fluidly connect to channels, cavities, etc.; however, this is not required. Once the medical device has been positioned on and / or inside the patient, one or more surface structures and / or microstructures may be used to engage and / or penetrate surrounding tissues 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 partially by a pharmaceutical agent and / or by a polymer. One or more of the surface structures and / or microstructures may include one or more internal channels, which may contain one or more materials (e.g., pharmaceutical agents, polymers, etc.); however, this is not required. One or more coatings and / or one or more surface structures and / or microstructures of the medical device 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 pharmaceutical agents, adhesives, labeling 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 pharmaceutical agents. One or more microstructures and / or surface structures may be biostable, biodegradable, etc.A medical device or one or more areas thereof may be at least partially covered and / or filled with a protective material to at least partially protect one or more areas 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 aforementioned polymers. The protective material may be 1) biostable and / or biodegradable and / or 2) porous and / or non-porous.

[0092] In another and / or alternative aspect of this disclosure, the medical device may optionally be an expandable device that can be expanded by using some other means (e.g., an airbag, etc.). The expandable medical device may be made of a material that does not have or substantially does not have shape memory properties.

[0093] According to another and / or alternative aspect of this disclosure, a near-net-shape forming process for frames or other metal components of medical devices is optionally provided. In a non-limiting embodiment of this disclosure, a method is provided to increase the post-sintering strength of a powder-pressed material by applying additional cold working. In one non-limiting embodiment, a green part is pressed and then sintered. Subsequently, the sintered part is pressed again to increase its mechanical strength by cold working the pressed and sintered part. Typically, the temperature during the pressing process following 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. Cold working occurs at temperatures not exceeding 150°C (e.g., 10°C–150°C and all values ​​and ranges therebetween). The shape changes of the sintered part after pressing need to be determined so that the final part (pressing, sintering, and repressing) meets the dimensional requirements of the final formed part. A method for improving the mechanical strength of pressed metal parts is also provided, which enhances the mechanical strength by repressing the sintered parts to perform additional cold working on the material. A method for pressing metal powder into near-net-shape or final parts is also provided. In one non-limiting embodiment, a method for manufacturing metal parts with predetermined porosity to produce beam-like or foam-like structures is provided, comprising mixing metal and polymer powders, pressing the powders into finished parts or semi-finished green parts, and then sintering the part under conditions where the polymer leaves behind metal through a thermal degradation process. 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 in which polymer residues remain on a metal substrate after thermal degradation, and the polymer residues possess some desired biological effects (e.g., promoting cell attachment and growth by encapsulating the metal with the body). The polymer and metal powders can have different sizes to create multiple pores—some large pores create channels for cell growth, and some small pores create ruff surfaces that promote cell attachment. Understandably, polymers can be dispersed uniformly or non-uniformly with metal powders. For example, if the final part has a uniform density and pore structure, the polymer material can be uniformly dispersed with the metal powder before the polymer and metal powder are consolidated and pressed together, and then the metal powder is sintered together to form a metal part or medical device.Alternatively, if the formed metal part or medical device has one or more channels, pathways, and / or voids on its 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 rather concentrated or forms all areas that will become one or more channels, pathways, 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 one or more such channels, pathways, and / or voids on the outer surface and / or within the formed part or medical device. Therefore, the combined use of polymers and metal powders, along with subsequent pressing and sintering, can be used to form novel and customized shapes or near-net-shape medical devices. Typically, prior to the sintering step, the polymer comprises about 0.1% to 70% by volume of the consolidated and pressed material (and all values ​​and ranges therebetween), and typically prior to the sintering step, the polymer comprises about 1% to 60% by volume of the consolidated and pressed material.

[0094] According to another and / or alternative aspect of this disclosure, the metal alloy used to at least partially form a medical device is initially formed as a billet, rod, tube, etc., and then finished into its 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 metal 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 metal forming the metal alloy to form a metal strip, and then rolling and welding the strip into a billet, rod, tube, etc.; 3) solidifying the metal powder of the metal alloy and / or the metal powder 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 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 limited. In one non-limiting process, near-net medical devices, near-net components of medical devices, blanks, rods, tubes, etc., may be formed from one or more metal or metal alloy ingots. In one non-limiting 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, blanks, rods, tubes, etc. In one non-limiting embodiment, the average particle size of the metal powder is less than about 230 mesh (e.g., less than 63 micrometers; 1 micrometer to 62 micrometers and all values ​​and ranges therebetween). In another and / or alternative non-limiting embodiment, the average particle size of the metal powder is about 2 micrometers to 62 micrometers, and more particularly about 5 micrometers to 49.9 micrometers. In another and / or alternative non-limiting embodiment, the average particle size of the metal powder is about 10 micrometers to 40 micrometers. In another and / or alternative non-limiting embodiment, the average density of the metal powder is greater than 5 g / cm³. 3 (For example, 5.001 g / cm) 3 Up to 19.3 g / cm 3 (and all values ​​and ranges therein). In another and / or alternative non-limiting embodiment, 10% to 100% by volume (and all values ​​and ranges therein) 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. Typically, the metal powder used to form the metal alloy has a carbon content of less than about 100 ppm, an oxygen content of less than about 50 ppm, and a nitrogen content of less than about 20 ppm. Typically, 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.

[0095] According to another and / or alternative aspect of this disclosure, when metal powders are consolidated to form a metal alloy as a billet, rod, tube, etc., the metal powders are pressed together to form a solid solution of the metal alloy as a near-net-shape medical device, a near-net-shape component of the medical device, a billet, rod, tube, etc. Typically, the pressing process is performed by isostatic pressing (i.e., applying uniform pressure to the metal powder from all sides); however, other processes may be used. When isostatically pressing metal powders together, cold isostatic pressing (CIP) is typically used to consolidate the metal powders; however, this is not necessary. The pressing process may be performed in an inert atmosphere, an oxygen-reducing atmosphere (e.g., a mixture of hydrogen, argon, and hydrogen), and / or under vacuum; however, this is not necessary. The near-net medical device, near-net component of the medical device, billet, rod, tube, etc., obtained by pressing metal powder together has an average density of 80%-95% (and all values ​​and ranges therebetween) of the final average density of the near-net medical device, near-net component of the medical device, billet, rod, 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 typically used. Typically, the pressing pressure is about 400 MPa-700 MPa; however, other pressures can be used. After pressing the metal powder together, the pressed metal powder is sintered to partially or completely fuse the metal powder together to form the near-net medical device, near-net component of the medical device, billet, rod, tube, etc. The sintering of the solidified metal powder can be carried out in an oxygen reducing atmosphere (e.g., helium, argon, hydrogen, mixtures of argon and hydrogen, etc.) and / or in a vacuum; however, this is not necessary. At high sintering temperatures, a high-hydrogen atmosphere reduces the amount of carbon and oxygen in the resulting near-net-shape medical devices, near-net-shape components, billets, rods, tubes, etc. Sintered metal powders typically have approximately 90%–99% of the minimum theoretical density of the metal alloy in the sintered state.

[0096] According to another and / or alternative aspect of this disclosure, when metal powder is used for 3D printing medical devices, parts of medical devices, blanks, rods, tubes, etc., the average particle size of the metal powder is optionally 2 micrometers to 62 micrometers, and more specifically about 5 micrometers to 49.9 micrometers, and the average density of the metal powder is greater than 5 g / cm³. 3 Furthermore, the metal powder is typically spherical, and the Hall flow rate (s / 50 g) is less than 30 seconds (e.g., 2 seconds to 29.99 seconds and all values ​​and ranges in between).

[0097] According to another and / or alternative aspect of this disclosure, after the near-clean medical device, near-clean components of the medical device, blanks, rods, tubes, etc. have been formed, the near-clean medical device, near-clean components of the medical device, blanks, rods, tubes, etc. may optionally be cleaned and / or polished; however, this is not required.

[0098] According to another and / or alternative aspect of this disclosure, the dimensions of near-net medical devices, near-net components of medical devices, blanks, rods, tubes, etc., can be adjusted to the required dimensions of the medical device. In one non-limiting embodiment, the cross-sectional area or diameter of the near-net medical device, near-net components of medical devices, blanks, rods, tubes, etc., is reduced to the final dimensions of the near-net medical device, near-net components of medical devices, blanks, rods, tubes, 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 components of medical devices, blanks, rods, tubes, 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 of the near-net medical device, near-net components of medical devices, blanks, rods, tubes, etc., can be reduced by using one or more drawing processes; however, this is not necessary. During the drawing process, care should be taken to prevent the formation of microcracks in the near-net medical device, near-net components of the medical device, billet, rod, tube, etc., while reducing the outer cross-sectional area or diameter of the near-net medical device, near-net components of the medical device, billet, rod, tube, etc.

[0099] According to another and / or alternative aspect of this disclosure, near-net-shape medical devices, near-net-shape components of medical devices, blanks, rods, tubes, etc., may optionally be nitrided during the drawing process; however, this is not mandatory. The nitrided layer on the near-net-shape medical devices, near-net-shape components of medical devices, blanks, rods, tubes, etc., can act as a lubricating surface during the drawing process to facilitate the drawing of the near-net-shape medical devices, near-net-shape components of medical devices, blanks, rods, tubes, etc. The near-net-shape medical devices, near-net-shape components of medical devices, blanks, rods, tubes, etc., are typically nitrided in the presence of nitrogen or a nitrogen mixture.

[0100] Using metal alloys 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: Compared to standard stainless steel, standard chromium-cobalt alloys, or standard titanium alloys, metal alloys offer increased strength and / or hardness. Therefore, a smaller amount of metal alloy can be used in a medical device to achieve similar strength compared to a medical device formed from a different metal. Consequently, by using metal alloys, the resulting medical device can be manufactured to be smaller and more compact without sacrificing its strength and durability. The medical device can also have a smaller profile, allowing it to be inserted into smaller areas, openings, and / or channels. Thinner metal alloy struts used to form the frame or other parts of the medical device can be used to create the frame or other parts that have the strength required for thicker struts or other structural elements of the medical device when formed from standard stainless steel, standard chromium-cobalt alloys, or standard titanium alloys.

[0101] The increased strength of metal alloys also leads to increased radial strength in medical devices. For example, medical devices can have thinner walls and achieve similar or improved radial strength compared to thick-walled medical devices made of standard stainless steel, standard cobalt-chromium alloys, or standard titanium alloys.

[0102] Compared to standard stainless steel or standard chromium-cobalt alloys, metal alloys offer improved stress-strain characteristics, bending properties, elongation properties, and / or flexibility properties in medical devices, thus leading to extended device lifespan. For example, medical devices can be used in areas subject to repeated bending. Due to the improved physical properties of medical devices made from metal alloys, they exhibit improved fracture resistance in such frequent bending environments. These improved physical properties are at least in part due to the composition of the metal alloy, its grain size, carbon, oxygen, and nitrogen content, and / or its carbon / oxygen ratio.

[0103] Compared to standard stainless steel, standard chromium-cobalt alloys, or standard titanium alloys, metal alloys can exhibit reduced springback during the compression and / or expansion of medical devices. Due to the use of metal alloys, medical devices formed from metal alloys better retain their compression form and / or better retain their expanded form after expansion. Therefore, when the medical device is compressed, when it is mounted onto a delivery device, and during insertion into the body channel, the medical device better maintains its smaller profile. Furthermore, the medical device better maintains its expanded profile after expansion, contributing to successful placement of the medical device in the treatment area.

[0104] Compared to medical devices made of standard stainless steel, standard chromium-cobalt alloys, or standard titanium alloys, the use of metal alloys in medical devices allows the medical device to better conform to irregularly shaped body channels when it expands within the body.

[0105] Compared to the cold working of standard stainless steel, standard chromium-cobalt alloys, or standard titanium alloys, metal alloys exhibit improved fatigue ductility when subjected to cold working.

[0106] Metal alloys offer improved durability compared to standard stainless steel, standard chromium-cobalt alloys, or standard titanium alloys.

[0107] Compared to standard stainless steel, standard chromium-cobalt alloys, or standard titanium alloys, metal alloys can have improved hydrophilicity.

[0108] Compared to standard stainless steel, standard chromium-cobalt alloys, or standard titanium alloys, metal alloys can have reduced ion release in body channels.

[0109] Compared to standard stainless steel, standard cobalt-chromium alloys, or standard titanium alloys, metal alloys are less irritating to the body, thus reducing inflammation, accelerating healing, and increasing the success rate of medical devices.

[0110] Compared to expandable frames made of standard stainless steel, standard cobalt-chromium alloys, and standard TiAlV alloys, medical devices comprising expandable metal frames at least partially formed of metal alloys exhibit reduced springback, improved flexural consistency, and greater radial strength, resulting in the following non-limiting advantages compared to expandable frames made of standard stainless steel, standard cobalt-chromium alloys, or standard TiAlV alloys: 1) the formation of frames for medical devices with thinner columns, struts, and / or strut joints, which leads to i) more... 1) Safe vascular access, and / or ii) reduced risk of bleeding and / or injury to the body passage and / or treatment area when the medical device is delivered to and / or dilated 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., vascular, aortic arch trauma, etc.) during insertion and / or dilation of the medical device at the treatment area, and / or ii) a reduced risk of neurological complications—stroke; 3) Less rebound, which results in i) a smaller grip profile size, ii) after dilation in the treatment area, the dilated medical device... iii) Increased consistency of the medical device at the treatment area; iv) Increased radial strength of the medical device frame after expansion at the treatment area; iv) Requires only a single gripping cycle to grip the medical device onto a balloon catheter or other type of delivery device; v) Reduced incidence of damage to components of the medical device (e.g., struts, columns, strut joints and / or other components of the expandable frame, leaflets, skirts, coatings, etc.) during gripping, expansion, and operation; vi) Larger effective orifice area (EOA) of the medical device after expansion; vi) In the medical device Pulmonary valve regurgitation (PVR) is reduced after expansion in the treatment area, and / or vii) only a single expansion cycle of the balloon on the balloon catheter or other expansion mechanism is required to fully expand the medical device; and / or 4) medical devices with superior 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 intravalvular thrombosis during the lifespan of the medical device, and / or v) reduce the incidence of infection during the lifespan of the medical device.

[0111] Medical devices incorporating the metal alloys according to this disclosure, such as expandable medical devices (e.g., expandable heart valves, stents, etc.), overcome several unmet needs present in expandable medical devices formed from standard cobalt-chromium alloys, standard TiAlV alloys, and standard stainless steel, namely: 1) eliminating the need to form large holes in aortic vessels or other blood vessels for initial insertion of the gripped medical device into 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 in anomalously shaped heart valves or through anomalously shaped arteries; 3) reducing the incidence of paravalvular leakage and / or other types of leakage around the implanted medical device when the medical device expands; 4) increasing the radial strength of the expansion struts, columns, and / or strut joints in the expandable frame, as well as the strength of the expandable frame itself after the medical device expands; 5) reducing the rebound of the expandable frame during gripping and / or expansion of the expandable frame of the medical device; and 6) enabling the medical device to be used with a permanent pacemaker. 7) Reduced incidence of minor stroke during insertion and manipulation of the medical device at the treatment area; 8) Reduced incidence of coronary ostial damage; 9) Improved fluoroscopic shortening; 10) Further reduction of aortic valve calcification and / or vascular calcification after medical device implantation; 11) Reduced need for multiple compression cycles when the medical device is inserted on a catheter or other type of delivery system; 12) Reduced incidence of frame / stent fracture during compression and / or expansion of the medical device; 13) Reduced incidence of biomembrane-endocarditis after medical device implantation; 14) Reduced allergic reactions to the medical device after medical device implantation; 15) Improved hydrophilicity of the medical device to improve tissue growth on and / or around the implanted medical device; 16) Reduced magnetization of the medical device; 17) Reduced toxicity of the medical device; 18) Reduced amount of metal ions released from the medical device; and / or 19) Extended lifespan of leaflets and / or stents / frames and / or other components of the medical device after medical device insertion.

[0112] A non-limiting object of this disclosure is to provide a metal alloy according to this disclosure that exhibits the rhenium effect and can optionally be used to partially or completely form a medical device.

[0113] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy according to this disclosure that exhibits the rhenium effect and contains at least 15 atomic weight% rhenium.

[0114] Another and / or alternative non-limiting object of this disclosure is to provide a method and process for forming a metal alloy according to this disclosure, the metal alloy exhibiting the rhenium effect and suppressing or preventing the formation of microcracks during the processing of the metal alloy.

[0115] Another and / or alternative non-limiting object of this disclosure is to provide a medical device formed partly or entirely of a metal alloy according to this disclosure, the metal alloy exhibiting the rhenium effect, and wherein the medical device has improved physical properties.

[0116] Another and / or alternative non-limiting object of this disclosure is to provide a medical device formed at least in part of a metal alloy according to this disclosure, the metal alloy exhibiting a rhenium effect, wherein the medical device has increased strength and / or hardness.

[0117] Another and / or alternative non-limiting object of this disclosure is to provide a method and process for forming a metal alloy according to this disclosure, the metal alloy exhibiting the rhenium effect and suppressing or preventing crack propagation and / or fatigue failure of the metal alloy.

[0118] Another and / or alternative non-limiting object of this disclosure is to provide a metal alloy exhibiting the rhenium effect, wherein the metal alloy comprises rhenium, molybdenum and one or more additional additives.

[0119] Another and / or alternative non-limiting object of this disclosure is to provide a metal alloy exhibiting the rhenium effect, wherein the metal alloy comprises rhenium, molybdenum, chromium, and optionally one or more additional additives.

[0120] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises rhenium, molybdenum and one or more additional additives; and wherein the medical device optionally includes an expandable frame.

[0121] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises rhenium, molybdenum, chromium, and optionally one or more additional additives; and wherein the medical device optionally includes an expandable frame.

[0122] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises 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.

[0123] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises rhenium, molybdenum, chromium, and optionally one or more additional additives; and wherein the medical device optionally comprises an expandable frame; wherein the expandable frame comprises a plurality of struts.

[0124] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy, wherein the metal alloy exhibits a rhenium effect and the metal alloy comprises rhenium, molybdenum and one or more alloy metals; and wherein the medical device includes an expandable frame; wherein the expandable frame is configured to be gripped to a gripped state such that the maximum outer diameter of the expandable frame in the gripped state is less than the maximum outer diameter of the expandable frame when fully expanded to the expanded state.

[0125] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, and the metal alloy comprising rhenium, molybdenum, chromium, and optionally one or more alloy metals; and wherein the medical device includes an expandable frame; wherein the expandable frame is configured to be gripped to a gripped state such that the maximum outer diameter of the expandable frame in the gripped state is less than the maximum outer diameter of the expandable frame when fully expanded to the expanded state.

[0126] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises rhenium, molybdenum and one or more alloy metals; and wherein the medical device includes an expandable frame; wherein the expandable frame has less than 5% rebound after undergoing a first gripping process.

[0127] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises rhenium, molybdenum, chromium, and optionally one or more alloy metals; and wherein the medical device includes an expandable frame; wherein the expandable frame has less than 5% rebound after undergoing a first gripping process.

[0128] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises rhenium, molybdenum and one or more alloy metals; and wherein the medical device includes an expandable frame; wherein the expandable frame has less than 5% springback after expanding from a gripped state to an expanded state.

[0129] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises rhenium, molybdenum, chromium, and optionally one or more alloy metals; and wherein the medical device comprises an expandable frame; wherein the expandable frame has less than 5% springback after expanding from a gripped state to an expanded state.

[0130] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises rhenium, molybdenum and one or more alloy metals; and wherein the metal alloy is hydrophilic, wherein the contact angle of a water droplet on the surface of the metal alloy is 25°-45° (and all values ​​and ranges therebetween).

[0131] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises rhenium, molybdenum, and one or more alloy metals; and wherein the maximum ion release of the major component of the metal alloy when inserted into or implanted in a patient's body does not exceed 0.5 µg / cm³ per day. 2 Furthermore, the main component of the rhenium alloy is the metal in the rhenium alloy, which accounts for at least 2% of the weight of the metal alloy.

[0132] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting a rhenium effect, wherein the metal alloy comprises rhenium, molybdenum, and one or more alloy metals; and wherein the absolute increase in ion release per dose of the metal alloy in tissues surrounding the medical device after insertion or implantation into or within the patient's body does not exceed 50 days.

[0133] Another and / or alternative non-limiting object of this disclosure is to provide a medical device comprising a metal alloy exhibiting the rhenium effect, wherein the medical device is an expandable stent or an expandable artificial heart valve.

[0134] Another and / or alternative non-limiting object of this 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, Pierce rolling, electroplating, electropolishing, machining, plasma coating, 3D printing coating, 3D printing, chemical vapor deposition, chemical polishing, cleaning, pickling, ion beam deposition or implantation, sputtering coating, vacuum deposition, etc. In one non-limiting embodiment, at least a portion or all of the medical device is formed by a 3D printing process.

[0135] Another and / or alternative non-limiting object of this disclosure is to provide a metal alloy comprising a unique combination of metals that exhibits a "rhenium effect" and results in: 1) a medical device having desired high ductility at approximately room temperature; 2) a medical device having desired tensile elongation; 3) a homogeneous or solid solution of a metal alloy having high radiometric impermeability; 4) reduced or prevented microcrack formation and / or fracture of the metal alloy of the tube of this disclosure when the tube is sized and / or cut to form a medical device or a portion thereof (e.g., a frame of a medical device); 5) reduced or prevented microcrack formation and / or fracture of the medical device or a portion thereof (e.g., a frame of a medical device) when the medical device or a portion thereof (e.g., a frame of a medical device) is crimped; and 6) reduced or prevented microcrack formation and / or fracture of the medical device or a portion thereof (e.g., a frame of a medical device) when the medical device is bent and / or expanded in a body channel. 7) Medical devices with desired ultimate tensile strength and yield strength, 8) Medical devices or parts of medical devices (e.g., frames of medical devices, etc.) having very thin wall thickness and still having the desired radial force required to keep the medical device or a part of the medical device (e.g., frames of medical devices, etc.) in the open state when expanded, 9) Medical devices or parts of medical devices (e.g., frames of medical devices, etc.) exhibiting less springback when pressed against a delivery system and / or expanded in a body channel, 10) Medical devices exhibiting improved conformity to the shape of the treatment area in the body channel when expanded in the body channel, 11) Medical devices exhibiting improved fatigue ductility, 12) Medical devices exhibiting reduced perspective shortening when expanded, and / or 13) Medical devices exhibiting improved durability.

[0136] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy in which the average grain size of the metallic alloy exhibiting the rhenium effect may be about 4 ASTM-20 ASTM, the tensile elongation of the metallic alloy may be about 25%-50%, the average density of the metallic alloy may be at least about 5 gm / cc, the average yield strength of the metallic alloy may be about 70-250 (ksi), the average ultimate tensile strength of the metallic alloy may be about 80 UTS-550 UTS (ksi), and the average Vickers hardness may be from 234 DPH to 700 DPH, or the Rockwell C hardness at 77℉ may be 19-60; however, this is not required.

[0137] Another and / or alternative non-limiting object of this disclosure is to provide a metal alloy comprising at least 15 atomic weight percent of rhenium; and wherein the metal alloy comprises one or more alloy 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 10% increased ductility and / or b) at least 10% increased tensile strength compared to said metal alloy without rhenium.

[0138] Another and / or alternative non-limiting object of this disclosure is to provide a metal alloy comprising at least 15 atomic weight percent rhenium and less than 50 weight percent rhenium; and wherein the metal alloy comprises one or more alloy 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 10% increased ductility and / or b) at least 10% increased tensile strength compared to said metal alloy without rhenium.

[0139] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy comprising at least 15 atomic weight % rhenium and 50 wt% to 78 wt% iron (and all values ​​and ranges therebetween), and a) 9 wt% to 27 wt% chromium (and all values ​​and ranges therebetween), b) 0.1 wt% to 26 wt% nickel (and all values ​​and ranges therebetween), c) 0.01 wt% to 7 wt% molybdenum (and all values ​​and ranges therebetween), d) 0.01 wt% to 16 wt% manganese (and all values ​​and ranges therebetween), e) 0.01 wt% to 4 wt% silicon (and all values ​​and ranges therebetween), f) 0.01 wt% to 2 wt% titanium (and all values ​​and ranges therebetween), g) 0.01 wt% to 1 wt% selenium (and all values ​​and ranges therebetween), h) 0.01 wt% to 1 wt% niobium (and all values ​​and ranges therebetween), i) One or more of the following: 0.01 wt% - 2 wt% aluminum (and all values ​​and ranges therein), j) 0.01 wt% - 1 wt% tantalum (and all values ​​and ranges therein), k) 0.01 wt% - 1 wt% cobalt (and all values ​​and ranges therein), l) 0.01 wt% - 5 wt% copper (and all values ​​and ranges therein), m) 0.01 wt% - 1 wt% vanadium (and all values ​​and ranges therein), and n) 0.01 wt% - 2 wt% tungsten (and all values ​​and ranges therein).

[0140] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy comprising at least 15 atomic weight percent rhenium and 35 to 68 wt percent cobalt (and all values ​​and ranges therebetween), and a) 12 to 28 wt percent chromium (and all values ​​and ranges therebetween), b) 0.01 to 38 wt percent nickel (and all values ​​and ranges therebetween), c) 0.1 to 30 wt percent molybdenum (and all values ​​and ranges therebetween), d) 0.01 to 2 wt percent manganese (and all values ​​and ranges therebetween), e) 0.01 to 1 wt percent silicon (and all values ​​and ranges therebetween), f) 0.01 to 18 wt percent tungsten (and all values ​​and ranges therebetween), g) 0.01 to 0.5 wt percent lanthanum (and all values ​​and ranges therebetween), h) 0.01 to 20 wt percent iron (and all values ​​and ranges therebetween), i) One or more of the following: 0.01 wt% - 5 wt% titanium (and all values ​​and ranges therein), j) 0.01 wt% - 2 wt% niobium (and all values ​​and ranges therein), k) 0.01 wt% - 2 wt% aluminum (and all values ​​and ranges therein), l) 0.01 wt% - 1 wt% silicon (and all values ​​and ranges therein), m) 0.01 wt% - 0.5 wt% boron (and all values ​​and ranges therein), and n) 0.01 wt% - 0.5 wt% silver (and all values ​​and ranges therein).

[0141] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy comprising at least 15 atomic weight percent rhenium and 70 wt percent to 91.5 wt percent titanium (and all values ​​and ranges therebetween), and a) 2 wt percent to 8 wt percent aluminum (and all values ​​and ranges therebetween), b) 0.01 wt percent to 16 wt percent vanadium (and all values ​​and ranges therebetween), c) 0.01 wt percent to 1 wt percent iron (and all values ​​and ranges therebetween), d) 0.01 wt percent to 0.5 wt percent yttrium (and all values ​​and ranges therebetween), e) 0.01 wt percent to 20 wt percent chromium (and all values ​​and ranges therebetween), f) 0.0 wt percent to 16 wt percent molybdenum (and all values ​​and ranges therebetween), g) 0.01 wt percent to 2 wt percent nickel (and all values ​​and ranges therebetween), h) One or more of the following: 0.01 wt% to 12 wt% tin (and all values ​​and ranges therein), i) 0.01 wt% to 6 wt% zirconium (and all values ​​and ranges therein), j) 0.01 wt% to 2 wt% tantalum (and all values ​​and ranges therein), k) 0.01 wt% to 4 wt% niobium (and all values ​​and ranges therein), l) 0.01 wt% to 1 wt% silicon (and all values ​​and ranges therein), m) 0.01 wt% to 3 wt% iron (and all values ​​and ranges therein).

[0142] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy comprising at least 15 atomic weight % rhenium, 35 wt% to 84 wt% tantalum (and all values ​​and ranges therebetween), and one or more of a) 0.1 wt% to 25 wt% tungsten (and all values ​​and ranges therebetween), b) 0.1 wt% to 55 wt% molybdenum (and all values ​​and ranges therebetween), c) 0.01 wt% to 45 wt% niobium (and all values ​​and ranges therebetween), d) 0.01 wt% to 5 wt% chromium (and all values ​​and ranges therebetween), f) 0.01 wt% to 5 wt% titanium (and all values ​​and ranges therebetween), g) 0.01 wt% to 5 wt% zirconium (and all values ​​and ranges therebetween), and h) 0.01 wt% to 4 wt% hafnium (and all values ​​and ranges therebetween).

[0143] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy comprising at least 15 atomic weight percent rhenium, 40 wt percent to 93 wt percent molybdenum (and all values ​​and ranges therein), and one or more of a) 0.1 wt percent to 50 wt percent tantalum (and all values ​​and ranges therein), b) 0.1 wt percent to 50 wt percent tungsten (and all values ​​and ranges therein), c) 0.01 wt percent to 5 wt percent hafnium (and all values ​​and ranges therein), d) 0.01 wt percent to 20 wt percent chromium (and all values ​​and ranges therein), e) 0.01 wt percent to 3 wt percent titanium (and all values ​​and ranges therein), and f) 0.01 wt percent to 2 wt percent zirconium (and all values ​​and ranges therein).

[0144] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy comprising at least 15 atomic weight percent rhenium, 40 to 85 wt percent tungsten (and all values ​​and ranges therebetween), and a) 0.01 to 50 wt percent molybdenum (and all values ​​and ranges therebetween), b) 0.01 to 50 wt percent tantalum (and all values ​​and ranges therebetween), d) 0.01 to 5 wt percent hafnium (and all values ​​and ranges therebetween), d) 0.01 to 50 wt percent copper (and all values ​​and ranges therebetween), e) 0.01 to 8 wt percent nickel (and all values ​​and ranges therebetween), f) 0.01 to 5 wt percent iron (and all values ​​and ranges therebetween), g) 0.01 to 50 wt percent zirconium (and all values ​​and ranges therebetween), and h) One or more of 0.01 wt% to 20 wt% chromium (and all values ​​and ranges therein).

[0145] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy comprising at least 15 atomic weight % rhenium, 40 wt% to 85 wt% niobium (and all values ​​and ranges therebetween), and one or more of a) 0.01 wt% to 20 wt% molybdenum (and all values ​​and ranges therebetween), b) 0.01 wt% to 35 wt% tantalum (and all values ​​and ranges therebetween), c) 0.01 wt% to 12 wt% hafnium (and all values ​​and ranges therebetween), d) 0.01 wt% to 5 wt% zirconium (and all values ​​and ranges therebetween), e) 0.01 wt% to 3 wt% titanium (and all values ​​and ranges therebetween), f) 0.01 wt% to 15 wt% tungsten (and all values ​​and ranges therebetween), and g) 0.01 wt% to 1 wt% yttrium (and all values ​​and ranges therebetween).

[0146] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy comprising at least 15 atomic weight % rhenium, 30 wt% to 58 wt% titanium (and all values ​​and ranges therebetween), and 30 wt% to 58 wt% nickel (and all values ​​and ranges therebetween).

[0147] Another and / or alternative non-limiting object of this disclosure is to provide a metallic alloy comprising at least 15 atomic weight percent rhenium and one or more of a) 1 atomic weight percent to 85 atomic weight percent chromium (and all values ​​and ranges therebetween), b) 0.1 atomic weight percent to 10 atomic weight percent titanium (and all values ​​and ranges therebetween), c) 0.1 atomic weight percent to 10 atomic weight percent molybdenum (and all values ​​and ranges therebetween), and d) 0.1 atomic weight percent to 10 atomic weight percent zirconium (and all values ​​and ranges therebetween).

[0148] Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings. Attached Figure Description

[0149] The following is a brief description of the accompanying drawings, which are provided to illustrate the exemplary embodiments disclosed herein and not to limit them.

[0150] 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 Implementation

[0151] Although specific terms are used in the following description for clarity, these terms are intended only to refer to the specific structures chosen for the embodiments illustrated in the accompanying drawings, and are not intended to limit or restrict the scope of this disclosure. In the drawings and the following description, it should be understood that the same reference numerals refer to parts having the same function.

[0152] The singular forms “a,” “an,” and “the” include plural indicators unless the context explicitly indicates otherwise.

[0153] As used in the specification and claims, the term "comprising" may include embodiments "consisting of" and "substantially consisting of". As used herein, the terms "comprising", "including", "having", "has", "may", "contains", and variations thereof refer to open-ended transitional phrases, terms, or words that require the presence of a specified ingredient / step and allow for the presence of other ingredients / steps. However, such a description should be interpreted as also describing the composition or method as "consisting of the listed ingredients / steps" and "substantially consisting of the listed ingredients / steps", which allows for the presence of only the specified ingredient / step and any unavoidable impurities that may arise therefrom, and excludes other ingredients / steps.

[0154] The numerical values ​​in the specification and claims of this application should be understood to include the same numerical values ​​when converted to the same number of significant figures, as well as numerical values ​​whose difference from the stated values ​​is less than the experimental error of conventional measurement techniques of the type described in this application for determining the values.

[0155] 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).

[0156] The terms “about” and “approximately” can be used for any numerical value that includes a variable but does not alter the basic function of the value. When used with a range, “about” and “approximately” also disclose a range defined by the absolute values ​​of the two endpoints; for example, “about 2 to about 4” also discloses a range of “2 to 4”. Typically, the terms “about” and “approximately” can refer to a number indicated by a positive or negative 10%.

[0157] Now for reference Figures 1-3 This example illustrates a comparison of the tensile strength, yield strength, and ductility of titanium alloys, cobalt-chromium alloys, and molybdenum-rhenium alloys. 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. Figures 1-3 As shown, the ductility of titanium and cobalt-chromium alloys decreases as their cross-sectional area is cold-worked and reduced. However, the ductility of molybdenum-rhenium alloys increases as their cross-sectional area is reduced. This increase in ductility is observed in other metal alloys containing rhenium. This increase in ductility of cold-worked metal alloys is known as the rhenium effect. When a metal alloy contains a sufficient amount of rhenium, it is found that the ductility of the rhenium-containing alloy a) decreases at a significantly smaller rate compared to the ductility of the alloy without a sufficient amount of rhenium, or b) increases compared to the decrease in ductility when compared to the ductility of the alloy without a sufficient amount of rhenium. The rhenium effect is observed in several metal alloys when the atomic weight of rhenium in the alloy is at least 15%.

[0158] Figures 1-3 The study also illustrates that the percentage increase in yield strength and tensile strength of molybdenum-rhenium alloys that have undergone cold working and have had their cross-sectional area reduced is greater than that of titanium alloys and cobalt-chromium alloys that have undergone similar cold working and have had their cross-sectional area reduced. After cold working of molybdenum-rhenium alloys and a 50% reduction in cross-sectional area, the yield tensile strength increases by approximately 33% (150 ksi to 200 ksi), and the yield strength increases by approximately 29% (175 ksi to 225 ksi). After cold working of molybdenum-rhenium alloys and a 100% reduction in cross-sectional area, the yield tensile strength increases by approximately 73% (150 ksi to 260 ksi), and the yield strength increases by approximately 71% (175 ksi to 300 ksi). The percentage increase in tensile strength of molybdenum-rhenium is greater than that of titanium alloys and cobalt-chromium alloys that have undergone similar cold working and have had their cross-sectional area reduced.

[0159] While the operations of exemplary embodiments of the disclosed methods may be described in a particular order for ease of presentation, it should be understood that the disclosed embodiments may include an order of operations other than the specific order disclosed. For example, the operations described in sequence may be rearranged or performed simultaneously in certain circumstances. Furthermore, the description and disclosure provided in connection with a particular embodiment are not limited to that embodiment and may be applied to any disclosed embodiment.

[0160] For simplicity, the accompanying drawings may not show the various ways in which the systems, methods, and apparatuses disclosed herein can be used in conjunction with other systems, methods, and apparatuses (which can be readily discerned by those skilled in the art based on this disclosure). Furthermore, the specification sometimes uses terms such as “produce” and “provide” to describe the disclosed methods. These terms are abstractions of actual, executable operations. The actual operations corresponding to these terms may vary depending on the specific implementation, and can be readily discerned by those skilled in the art based on this disclosure.

[0161] Therefore, it can be seen that the foregoing objectives, which are obvious from the preceding description, are effectively achieved. Since certain changes can be made to the described structure without departing from the spirit and scope of this disclosure, all content contained in the foregoing description and shown in the accompanying drawings should be interpreted as illustrative rather than restrictive. This disclosure has been described with reference to preferred and alternative embodiments. Modifications and variations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the disclosure provided herein. This disclosure is intended to include all such modifications and variations, provided they fall within the scope of this disclosure. It should also be understood that the following claims are intended to cover all general and specific features of this disclosure described herein, as well as all statements regarding the scope of this disclosure, which, in terms of language, may fall somewhere in between.

[0162] In order to assist the Patent Office and any reader of this application and any resulting patent in interpreting the appended claims, the applicant does not wish any appended claims or claim elements to reference 35 USC 112(f) unless the words “means for…” or “steps for…” are expressly used in a particular claim.

Claims

1. A metal alloy comprising rhenium in an amount of at least 15 atomic weight percent of the metal alloy; the total weight percentage of rhenium and the alloy metal being at least 70 weight percent of the metal alloy; the metal alloy a) having at least 10% increased ductility and / or b) at least 10% increased tensile strength compared to the rhenium-free metal alloy; the metal alloy comprising: I) At least 15 atomic weight percent rhenium and 50 to 78 wt percent iron, and one or more of the following a) to n): a) 9 to 27 wt percent chromium, b) 0.1 to 26 wt percent nickel, c) 0.01 to 7 wt percent molybdenum, d) 0.01 to 16 wt percent manganese, e) 0.01 to 4 wt percent silicon, f) 0.01 to 2 wt percent titanium, g) 0.01 to 1 wt percent selenium, h) 0.01 to 1 wt percent niobium, i) 0.01 to 2 wt percent aluminum, j) 0.01 to 1 wt percent tantalum, k) 0.01 to 1 wt percent cobalt, l) 0.01 to 5 wt percent copper, m) 0.01 to 1 wt percent vanadium and n) 0.01 wt% - 2 wt% tungsten; or II) At least 15 atomic weight percent rhenium and 35 to 68 wt percent cobalt, and one or more of the following a) to n): a) 12 to 28 wt percent chromium, b) 0.01 to 38 wt percent nickel, c) 0.1 to 30 wt percent molybdenum, d) 0.01 to 2 wt percent manganese, e) 0.01 to 1 wt percent silicon, f) 0.01 to 18 wt percent tungsten, g) 0.01 to 0.5 wt percent lanthanum, h) 0.01 to 20 wt percent iron, i) 0.01 to 5 wt percent titanium, j) 0.01 to 2 wt percent niobium, k) 0.01 to 2 wt percent aluminum, l) 0.01 to 1 wt percent silicon, m) 0.01 to 0.5 wt percent boron and n) 0.01% - 0.5% silver by weight; or III) At least 15 atomic weight percent rhenium and 70 to 91.5 wt percent titanium, and one or more of the following a) to m): a) 2 to 8 wt percent aluminum, b) 0.01 to 16 wt percent vanadium, c) 0.01 to 1 wt percent iron, d) 0.01 to 0.5 wt percent yttrium, e) 0.01 to 20 wt percent chromium, f) 0 to 16 wt percent molybdenum, g) 0.01 to 2 wt percent nickel, h) 0.01 to 12 wt percent tin, i) 0.01 to 6 wt percent zirconium, j) 0.01 to 2 wt percent tantalum, k) 0.01 to 4 wt percent niobium, l) 0.01 to 1 wt percent silicon and m) 0.01 to 3 wt percent iron; or IV) At least 15 atomic weight percent rhenium, 35 to 84 wt percent tantalum, and one or more of the following a) to h): a) 0.1 to 25 wt percent tungsten, b) 0.1 to 30 wt percent molybdenum, c) 0.01 to 45 wt percent niobium, d) 0.01 to 5 wt percent chromium, f) 0.01 to 5 wt percent titanium, g) 0.01 to 5 wt percent zirconium and h) 0.01 to 4 wt percent hafnium; or V) At least 15 atomic weight percent rhenium, 40 to 85 wt percent niobium, and one or more of the following a) to g): a) 0.01 to 20 wt percent molybdenum, b) 0.01 to 35 wt percent tantalum, c) 0.01 to 12 wt percent hafnium, d) 0.01 to 5 wt percent zirconium, e) 0.01 to 3 wt percent titanium, f) 0.01 to 15 wt percent tungsten, and g) 0.01 to 1 wt percent yttrium; or VI) At least 15 atomic weight percent rhenium, 30 to 58 wt percent titanium and 30 to 58 wt percent nickel; or VII) At least 15 atomic weight percent rhenium, and one or more of the following a) to d): a) 1 atomic weight percent to 85 atomic weight percent chromium, b) 0.1 atomic weight percent to 10 atomic weight percent titanium, c) 0.1 atomic weight percent to 10 atomic weight percent molybdenum and d) 0.1 atomic weight percent to 10 atomic weight percent zirconium.

2. The metal alloy of claim 1, wherein the metal alloy contains up to 75% rhenium by weight.

3. The metal alloy of claim 1, wherein the metal alloy contains less than 35% rhenium by weight.

4. The metal alloy of claim 1, wherein the metal alloy contains less than 25% rhenium by weight.

5. A medical device formed, in whole or in part, of a metal alloy, said metal alloy comprising at least 15 atomic weight percent of rhenium; the total weight percentage of rhenium and the alloy metal being at least 70 weight percent of said metal alloy; said metal alloy a) has at least 10% increased ductility and / or b) at least 10% increased tensile strength compared to said metal alloy without rhenium; said metal alloy comprising: I) At least 15 atomic weight percent rhenium and 50 to 78 wt percent iron, and one or more of the following a) to n): a) 9 to 27 wt percent chromium, b) 0.1 to 26 wt percent nickel, c) 0.01 to 7 wt percent molybdenum, d) 0.01 to 16 wt percent manganese, e) 0.01 to 4 wt percent silicon, f) 0.01 to 2 wt percent titanium, g) 0.01 to 1 wt percent selenium, h) 0.01 to 1 wt percent niobium, i) 0.01 to 2 wt percent aluminum, j) 0.01 to 1 wt percent tantalum, k) 0.01 to 1 wt percent cobalt, l) 0.01 to 5 wt percent copper, m) 0.01 to 1 wt percent vanadium and n) 0.01 wt% - 2 wt% tungsten; or II) At least 15 atomic weight percent rhenium and 35 to 68 wt percent cobalt, and one or more of the following a) to n): a) 12 to 28 wt percent chromium, b) 0.01 to 38 wt percent nickel, c) 0.1 to 30 wt percent molybdenum, d) 0.01 to 2 wt percent manganese, e) 0.01 to 1 wt percent silicon, f) 0.01 to 18 wt percent tungsten, g) 0.01 to 0.5 wt percent lanthanum, h) 0.01 to 20 wt percent iron, i) 0.01 to 5 wt percent titanium, j) 0.01 to 2 wt percent niobium, k) 0.01 to 2 wt percent aluminum, l) 0.01 to 1 wt percent silicon, m) 0.01 to 0.5 wt percent boron and n) 0.01% - 0.5% silver by weight; or III) At least 15 atomic weight percent rhenium and 70 to 91.5 wt percent titanium, and one or more of the following a) to m): a) 2 to 8 wt percent aluminum, b) 0.01 to 16 wt percent vanadium, c) 0.01 to 1 wt percent iron, d) 0.01 to 0.5 wt percent yttrium, e) 0.01 to 20 wt percent chromium, f) 0 to 16 wt percent molybdenum, g) 0.01 to 2 wt percent nickel, h) 0.01 to 12 wt percent tin, i) 0.01 to 6 wt percent zirconium, j) 0.01 to 2 wt percent tantalum, k) 0.01 to 4 wt percent niobium, l) 0.01 to 1 wt percent silicon and m) 0.01 to 3 wt percent iron; or IV) At least 15 atomic weight percent rhenium, 35 to 84 wt percent tantalum, and one or more of the following a) to h): a) 0.1 to 25 wt percent tungsten, b) 0.1 to 30 wt percent molybdenum, c) 0.01 to 45 wt percent niobium, d) 0.01 to 5 wt percent chromium, f) 0.01 to 5 wt percent titanium, g) 0.01 to 5 wt percent zirconium and h) 0.01 to 4 wt percent hafnium; or V) At least 15 atomic weight percent rhenium, 40 to 85 wt percent niobium, and one or more of the following a) to g): a) 0.01 to 20 wt percent molybdenum, b) 0.01 to 35 wt percent tantalum, c) 0.01 to 12 wt percent hafnium, d) 0.01 to 5 wt percent zirconium, e) 0.01 to 3 wt percent titanium, f) 0.01 to 15 wt percent tungsten, and g) 0.01 to 1 wt percent yttrium; or VI) At least 15 atomic weight percent rhenium, 30 to 58 wt percent titanium and 30 to 58 wt percent nickel; or VII) At least 15 atomic weight percent rhenium, and one or more of the following a) to d): a) 1 atomic weight percent to 85 atomic weight percent chromium, b) 0.1 atomic weight percent to 10 atomic weight percent titanium, c) 0.1 atomic weight percent to 10 atomic weight percent molybdenum and d) 0.1 atomic weight percent to 10 atomic weight percent zirconium.

6. The medical device of claim 5, wherein the metal alloy comprises up to 75% rhenium by weight.

7. The medical device of claim 5, wherein the metal alloy contains less than 35% rhenium by weight.

8. The medical device of claim 5, wherein the metal alloy contains less than 25% rhenium by weight.

9. The medical device of claim 5, wherein at least one region of the medical device comprises at least one biological agent.

10. The medical device of claim 5, wherein at least one region of the medical device comprises at least one polymer.

11. The medical device of claim 5, wherein at least one region of the medical device comprises at least one polymer, the at least one polymer at least partially coating, encapsulating, or a combination thereof, the at least one biological agent.

12. A medical device formed, partially or entirely, of a metal alloy, said metal alloy comprising rhenium in an amount of at least 15 atomic weight percent of the metal alloy; said metal alloy comprising one or more alloy metals selected from the group consisting of aluminum, boron, beryllium, bismuth, cadmium, calcium, cerium, chromium, cobalt, copper, gallium, gold, hafnium, iridium, iron, lanthanum, lithium, magnesium, manganese, nickel, niobium, osmium, palladium, platinum, rare earth metals, rhodium, ruthenium, scandium, silver, silicon, tantalum, technetium, tin, titanium, tungsten, vanadium, yttrium, zinc, and zirconium; the total weight percentage of rhenium and the alloy metal being at least 70 weight percent of said metal alloy; said metal alloy a) has at least 10% increased ductility and / or b) at least 10% increased tensile strength compared to said metal alloy without rhenium; said medical device comprising an expandable frame, said expandable... The frame is formed of the metal alloy; the expandable frame includes a plurality of pillars; the expandable frame is configured to be gripped to a gripped state such that the maximum outer diameter of the expandable frame in the gripped state is smaller than the maximum outer diameter of the expandable frame when fully expanded to the expanded state; a) the expandable frame has less than 5% springback after undergoing a first gripping process; b) the expandable frame has less than 5% springback after expanding from the gripped state to the expanded state; c) the metal alloy is hydrophilic, wherein the contact angle of water droplets on the surface of the metal alloy is 25°-45°; d) the maximum ion release of the major components of the metal alloy when inserted or implanted into the patient's body does not exceed 0.5 µg / cm³ per day. 2 The major component comprises at least 2% by weight of the metal alloy; and / or e) the absolute increase in ion release per dose of the metal alloy in the tissue surrounding the medical device after insertion or implantation into the patient's body or within the patient's body does not exceed 50 days.

13. The medical device of claim 12, wherein the metal alloy a) has at least 10% increased ductility and / or b) at least 10% increased tensile strength compared to the rhenium-free metal alloy; the metal alloy comprises: I) At least 15 atomic weight percent rhenium and 50 to 78 wt percent iron, and one or more of the following a) to n): a) 9 to 27 wt percent chromium, b) 0.1 to 26 wt percent nickel, c) 0.01 to 7 wt percent molybdenum, d) 0.01 to 16 wt percent manganese, e) 0.01 to 4 wt percent silicon, f) 0.01 to 2 wt percent titanium, g) 0.01 to 1 wt percent selenium, h) 0.01 to 1 wt percent niobium, i) 0.01 to 2 wt percent aluminum, j) 0.01 to 1 wt percent tantalum, k) 0.01 to 1 wt percent cobalt, l) 0.01 to 5 wt percent copper, m) 0.01 to 1 wt percent vanadium and n) 0.01 wt% - 2 wt% tungsten; or II) At least 15 atomic weight percent rhenium and 35 to 68 wt percent cobalt, and one or more of the following a) to n): a) 12 to 28 wt percent chromium, b) 0.01 to 38 wt percent nickel, c) 0.1 to 30 wt percent molybdenum, d) 0.01 to 2 wt percent manganese, e) 0.01 to 1 wt percent silicon, f) 0.01 to 18 wt percent tungsten, g) 0.01 to 0.5 wt percent lanthanum, h) 0.01 to 20 wt percent iron, i) 0.01 to 5 wt percent titanium, j) 0.01 to 2 wt percent niobium, k) 0.01 to 2 wt percent aluminum, l) 0.01 to 1 wt percent silicon, m) 0.01 to 0.5 wt percent boron and n) 0.01% - 0.5% silver by weight; or III) At least 15 atomic weight percent rhenium and 70 to 91.5 wt percent titanium, and one or more of the following a) to m): a) 2 to 8 wt percent aluminum, b) 0.01 to 16 wt percent vanadium, c) 0.01 to 1 wt percent iron, d) 0.01 to 0.5 wt percent yttrium, e) 0.01 to 20 wt percent chromium, f) 0 to 16 wt percent molybdenum, g) 0.01 to 2 wt percent nickel, h) 0.01 to 12 wt percent tin, i) 0.01 to 6 wt percent zirconium, j) 0.01 to 2 wt percent tantalum, k) 0.01 to 4 wt percent niobium, l) 0.01 to 1 wt percent silicon and m) 0.01 to 3 wt percent iron; or IV) At least 15 atomic weight percent rhenium, 35 to 84 wt percent tantalum, and one or more of the following a) to h): a) 0.1 to 25 wt percent tungsten, b) 0.1 to 30 wt percent molybdenum, c) 0.01 to 45 wt percent niobium, d) 0.01 to 5 wt percent chromium, f) 0.01 to 5 wt percent titanium, g) 0.01 to 5 wt percent zirconium and h) 0.01 to 4 wt percent hafnium; or V) At least 15 atomic weight percent rhenium, 40 to 85 wt percent niobium, and one or more of the following a) to g): a) 0.01 to 20 wt percent molybdenum, b) 0.01 to 35 wt percent tantalum, c) 0.01 to 12 wt percent hafnium, d) 0.01 to 5 wt percent zirconium, e) 0.01 to 3 wt percent titanium, f) 0.01 to 15 wt percent tungsten, and g) 0.01 to 1 wt percent yttrium; or VI) At least 15 atomic weight percent rhenium, 30 to 58 wt percent titanium and 30 to 58 wt percent nickel; or VII) At least 15 atomic weight percent rhenium, and one or more of the following a) to d): a) 1 atomic weight percent to 85 atomic weight percent chromium, b) 0.1 atomic weight percent to 10 atomic weight percent titanium, c) 0.1 atomic weight percent to 10 atomic weight percent molybdenum and d) 0.1 atomic weight percent to 10 atomic weight percent zirconium; The medical device includes an expandable frame formed of the metal alloy; the expandable frame includes a plurality of pillars; the expandable frame is configured to be gripped to a gripped state such that the maximum outer diameter of the expandable frame in the gripped state is smaller than the maximum outer diameter of the expandable frame when fully expanded to the expanded state; a) the expandable frame has less than 5% rebound after undergoing a first gripping process; b) the expandable frame has less than 5% rebound after expanding from the gripped state to the expanded state; c) the metal alloy is hydrophilic, 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 major component of the metal alloy when inserted or implanted into a patient's body does not exceed 0.5 µg / cm³ per day. 2 The major component comprises at least 2% by weight of the metal alloy; and / or e) the absolute increase in ion release per dose of the metal alloy in the tissue surrounding the medical device after insertion or implantation into the patient's body or within the patient's body does not exceed 50 days.

14. A rhenium-containing metal alloy, said metal alloy comprising: I) At least 15 atomic weight percent rhenium, at least 50 wt percent iron, and one or more alloy metals selected from a) to m) of Alloy I: a) 10 wt percent to 28 wt percent chromium, b) 0 wt percent to 35 wt percent nickel, c) 0 wt percent to 4 wt percent molybdenum, d) 0 wt percent to 2 wt percent manganese, e) 0 wt percent to 0.75 wt percent silicon, f) 0 wt percent to 5 wt percent titanium, g) 0 wt percent to 10 wt percent niobium, h) 0 wt percent to 5 wt percent copper, i) 0 wt percent to 4 wt percent aluminum, j) 0 wt percent to 10 wt percent tantalum, k) 0 wt percent to 1 wt percent selenium, l) 0 wt percent to 2 wt percent vanadium, and m) 0 wt percent to 2 wt percent tungsten; wherein the total weight percentage of said rhenium, iron, and said alloy I alloy metal is greater than 95 wt%; or II) At least 15 atomic weight percent rhenium, 30 to 68 wt percent cobalt, 15 to 32 wt percent chromium, and one or more alloy II alloy metals selected from a) to j): a) 1 to 36 wt percent nickel, b) 2 to 18 wt percent molybdenum, c) 0 to 18 wt percent iron, d) 0 to 1 wt percent titanium, e) 0 to 0.15 wt percent manganese, f) 0 to 0.15 wt percent silver, g) 0 to 16 wt percent tungsten, h) 0 to 2 wt percent silicon, i) 0 to 2 wt percent aluminum, and j) 0 to 1 wt percent iron; wherein the total weight percentage of said rhenium, cobalt, chromium, and said alloy II alloy metal is greater than 95 wt%; or III) At least 15 atomic weight percent rhenium, 5.5 wt%–6.75 wt% aluminum, 3.5 wt%–4.5 wt% vanadium, 85 wt%–93 wt% titanium, and one or more alloy metals selected from a) to b) of Alloy III: a) 0 wt%–0.4 wt% iron, b) 0 wt%–0.05 wt% yttrium; wherein the total weight percentage of said rhenium, aluminum, vanadium, titanium, and said alloy metal of Alloy III is greater than 95 wt%; or IV) At least 15 atomic weight percent rhenium, 40 to 85 wt percent niobium, and one or more alloy IV alloy metals selected from a) to g): a) 0.01 to 20 wt percent molybdenum, b) 0.01 to 35 wt percent tantalum, c) 0.01 to 12 wt percent hafnium, d) 0.01 to 5 wt percent zirconium, e) 0.01 to 3 wt percent titanium, f) 0.01 to 15 wt percent tungsten, and g) 0.01 to 1 wt percent yttrium; wherein the total weight percentage of said rhenium, niobium, and said alloy IV alloy metal is greater than 95 wt%; or VI) At least 15 atomic weight percent rhenium, 30 wt percent to 58 wt percent titanium, and 30 wt percent to 58 wt percent nickel; wherein the total weight percentage of said rhenium, titanium, and nickel is greater than 95 wt%; or VII) at least 15 atomic weight percent rhenium, and one or more of a) to d): a) 1 atomic weight percent to 85 atomic weight percent chromium, b) 0.1 atomic weight percent to 10 atomic weight percent titanium, c) 0.1 atomic weight percent to 10 atomic weight percent molybdenum, and d) 0.1 atomic weight percent to 10 atomic weight percent zirconium; wherein the total weight percentage of said rhenium, chromium, titanium, molybdenum and zirconium is greater than 95 by weight.

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