One aspect of the present disclosure provides a method of manufacturing an orthopedic prosthesis. This particular method includes providing a porous metal layer (22) positioned against a metal substrate at an interface between the porous metal layer and the metal substrate. Additional steps include providing an electrode (132) and providing an intermediate element or coating positioned between and in contact with the electrode and the porous metal layer where the intermediate element includes tantalum in contact with tantalum of the porous metal layer. In a further step, an electrical current is directed to the interface between the porous metal layer and the metal substrate to bond the porous metal layer to the metal substrate.
