Integrity and thermal decomposition of apatite in coatings influenced by underlying titanium during plasma spraying and post-heat-treatment

Surface nanocrystallization of hydroxyapatite coating

Nanocharactered biomaterials, such as nanopowders, nanocrystalline compacts and nanostructured films, as well as materials with nanoscale roughness, have attracted much attention recently, due to their clear effects on cell response. Surface nanocrystallization of plasma-sprayed hydroxyapatite (HA) coating can be realized by conventional post-heat treatment. This study reveals that 20-30nm nanocrystals formed on HA coatings post-heat treated at 650 degrees C, and the increase in holding time increased the number of surface nanocrystals and intensified their aggregation. Hard aggregation occurred when HA coatings were repetitively post-heat treated. This indicates that the surface nanocrystallization is controllable. Cell experiments were carried out with rat calvarial osteoblasts. The post-heat treated HA coatings exhibit an obviously better osteoblast response than the as-sprayed coatings. Well-flattened cells attached themselves to the coating surfaces, with a good interaction between their filopodia and the nanocrystallized region. It is proposed that the surface nanocrystallization should be taken into account when the post-heat treatment process is introduced for the fabrication of HA coatings.

Cell-compatible properties of calcium carbonates and hydroxyapatite deposited on ultrathin poly(vinyl alcohol)-coated polyethylene films

Poly(vinyl alcohol) (PVA) was coated onto polyethylene (PE) films by a repetitive adsorption and drying process, and then the PVA-coated PE films were alternately immersed into aqueous solutions of Ca2+ and CO3(2-) ions (alternate soaking cycles), to deposit calcium carbonate (CaCO3) onto the films. The PVA coating was essential for the CaCO3 deposition. The amount of CaCO3 deposited increased with an increasing number of cycles. Scanning electron microscopic observations and attenuated total reflection spectra revealed the presence of both calcite and aragonite as the crystal structures of CaCO3 on the film. L929 fibroblast cells adhered and proliferated on these CaCO3-deposited PE films, as well as the hydroxyapatite-coated PE films previously prepared. It was found that the PVA coating and the subsequent deposition of calcium salts on certain films facilitated cell compatibility.

Hydroxyapatite deposition by alternating soaking technique on poly(vinyl alcohol)-coated polyethylene films

A poly(vinyl alcohol) (PVA)-coating on polyethylene films, prepared by repetitive adsorption/drying in an aqueous PVA solution, accelerated hydroxyapatite (HAp) deposition by an altemate soaking in aqueous solutions containing Ca2+ and PO4(3-) ions. X-ray photoelectron spectra of the surface of the HAp-deposited film showed the presence of calcium and phosphorus of a suitable peak ratio for HAp formation. X-ray diffraction analyses also revealed peaks corresponding to HAp. Scanning electron microscopic observation showed the surface of the HAp layer to be smooth, with nano-ordered dotted threads in networks. A simple PVA coating on a surface will serve as a novel system for accelerated HAp formation via alternating soaking.

Effect of spark plasma sintering on the microstructure and in vitro behavior of plasma sprayed HA coatings

The crystalline phases and degree of crystallinity in plasma sprayed calcium phosphate coatings on Ti substrates are crucial factors that influence the biological interactions of the materials in vivo. In this study, plasma sprayed hydroxyapatite (HA) coatings underwent post-spray treatment by the spark plasma sintering (SPS) technique at 500 degrees C, 600 degrees C, and 700 degrees C for duration of 5 and 30 min. The activity of the HA coatings before and after SPS are evaluated in vitro in a simulated body fluid. The surface microstructure, crystallinity, and phase composition of each coating is characterized by scanning electron microscopy and X-ray diffractometry before, and after in vitro incubation. Results show that the plasma sprayed coatings treated for 5 min in SPS demonstrated increased proportion of beta-TCP phase with a preferred-orientation in the (214) plane, and the content of beta-TCP phase corresponded to SPS temperature, up to 700 degrees C. SPS treatment at 700 degrees C for 30 min enhanced the HA content in the plasma spray coating as well. The HA coatings treated in SPS for 5 min revealed rapid surface morphological changes during in vitro incubation (up to 12 days), indicating that the surface activity is enhanced by the SPS treatment. The thickest apatite layer was found in the coating treated by SPS at 700 degrees C for 5 min.

Hydroxyapatite-coated Ti-6Al-4V part 2: the effects of post-deposition heat treatment at low temperatures

The present investigation explores the effects of a 90-h post-deposition annealing treatment at 400 degrees C in air on the crystallographic and chemical properties of a plasma-sprayed hydroxyapatite (HA) coating, the thickness and composition of the interfacial oxide layer, and the fatigue behaviour of the underlying Ti-6Al-4V substrate. X-ray diffraction analysis revealed that significant recovery of the crystalline HA structure occurred as a result of the treatment, however, as compared with results obtained through treatment at higher temperatures, recovery obtained through use of the present treatment was incomplete. X-ray photoelectron spectroscopy analysis showed no changes in the constituents of the oxide layer, with the oxide species TiO2, Al2O3, V2O5, V2O3, and VO2 present on both the as-sprayed and the heat-treated substrates. A change in film thickness was observed, however, as evidenced by a change in colour from opaque bronze to dark purple. The fatigue resistance of the substrate was found to be significantly reduced by the heat treatment, with the lives of heat-treated coupons with coatings of all thicknesses closely resembling those of as-sprayed coupons with thick HA coatings and uncoated stress-relieved coupons presented in Part I of this study. Stress relief was identified as the most likely cause of these reductions.

Effect of vapor-flame treatment on plasma sprayed hydroxyapatite coatings

A vapor-flame treatment was developed to modify the crystallinity of the as-sprayed hydroxyapatite (HA) coatings. The effects of the treatment on composition, structure, and properties of HA coatings were investigated. Results showed that the vapor-flame treatment is simple and efficient to adjust the crystallinity of as-sprayed HA coating. Its crystallinities can be raised from 53.5 to 98.7% in 3-7 min. The porosities of coatings increased with an increase in the vapor-flame treating time. The microhardness of coating decreased as a result of this treatment. It may be explained in terms of the extent of microcracks caused by recrystallization of amorphous HA and relaxation of stress of the coating. The porosity, bonding strength, and hardness of HA coatings treated for 7 min were 15.7%, 32.0 MPa (300 microm thickness), and 1.9 GPa, respectively.

A methodological study for the analysis of apatite-coated dental implants retrieved from humans

The stability of thermally processed hydroxyapatite coatings for oral and orthopedic bioprostheses has been questioned. Information on the chemical changes, which occur with hydroxyapatite biomaterials post-implantation in humans, is lacking. The purpose of this investigation was to begin to examine post-implantation surface changes of hydroxyapatite-coated implants using scanning electron microscopy (SEM), x-ray microanalysis (EDAX), Fourier transform infrared spectroscopy (FTIR), and x-ray diffraction (XRD). Three retrieved dental implant specimens from humans following clinical failure due to peri-implantitis were examined. Unimplanted cylinders served as controls. Clinically, the retrieved specimens were all enveloped by a fibrous tissue capsule with bone present at the apical extent of the implant. SEM analysis showed that the retrieved surfaces were coated with both calcified and proteinaceous deposits. EDAX scans of the retrieved specimens demonstrated evidence of hydroxyapatite coating loss reflected by increasing titanium and aluminum signals. Other foreign ions such as sodium, chloride, sulfur, silica, and magnesium were detected. XRD of the control specimens showed that the samples were predominantly apatite; however, two peaks were detected in the diffraction pattern, which are not characteristic of hydroxyapatite, indicating that small amounts of one or more other crystalline phases were also present. The retrieved specimens showed slightly larger average crystal size relative to the control sample material, and the non-apatite lines were not present. FTIR evaluation of the retrieved specimens revealed the incorporation of carbonate and organic matrix on or into the hydroxyapatite. Narrowing of and increased detail in the phosphate peaks indicated an increase in average crystal size and/or perfection relative to the controls, as did the XRD results. Based on these results, we conclude that chemical changes may occur within the coating, with the incorporation of carbonate and concomitant reduction in hydroxyapatite coating thickness. Thermodynamic dissolution-reprecipitation of the coating itself and subsequent surface insult by bacterial and local inflammatory components may be involved with these changes.

Apatite formation on/in hydrogel matrices using an alternate soaking process (III): effect of physico-chemical factors on apatite formation on/in poly(vinyl alcohol) hydrogel matrices

The aim of this study is to clarify the physico-chemical factors which influence apatite formation on/in a hydrogel during a novel alternate soaking process. A poly(vinyl alcohol) (PVA) gel was used as a model matrix. The amount of apatite formed on/in PVA gels decreased with an increase in the reaction temperature during the same reaction cycles. This suggested that the equilibrium swelling ratios decreased with increasing reaction temperatures; that is, the diffusion of calcium and phosphate ions reduced at high reaction temperature. However, the crystallinity of apatite formed on/in PVA gels was greater at higher reaction temperatures. The amount of apatite formed on/in PVA gels increased with an increase in the calcium and phosphate solution concentrations, and increased by shaking at the first three reaction cycles. A few influences could be observed when the solution volume was changed, however, the soaking order was not effective in this study. These results indicate that the amount of apatite formation on/in PVA gels can be controlled by changing the reaction temperature and the Ca- and P-solution concentrations, and that the crystallinity of apatite can be also changed by controlling the reaction temperatures.

A study on hydroxyapatite formation on/in the hydroxyl groups-bearing nonionic hydrogels

Using the biomimetic method, we formed a hydroxyapatite (HAp) layer on/in certain types of nonionic hydrogels that contain hydroxyl groups. The hydrogels used were poly(vinyl alcohol) (PVA), poly(2-hydroxyethyl methacrylate) (PHEMA), poly(glucosyloxyethyl methacrylate) (PGEMA), and agarose. Under an optical microscope, we observed a thin, continuous HAp layer on the top surface of the PVA, PHEMA, and PGEMA gels. On the other hand, we only observed an intermittent HAp layer on the surface of the agarose gel. The swelling ratio and the bound water content of these hydrogels were measured as an essential character in HAp formation. There was some relation among the HAp formation, the swelling ratios, and the bound water content.

Differences in microstructural characteristics of dense HA and HA coating

Two implant types of hydroxyapatite (HA) currently are available for dental implants: dense HA-cemented titanium (Ti) and HA-coated. It has been shown in previous reports that there are differences in the chemical and mechanical stabilities between the dense HA and HA coated. The differences are thought to be due to structural differences between the two ceramic types. The aim of this study was to investigate the differences in microstructural characteristics of currently available dense HA and HA coated implants before implantation and at periods of 3 weeks and 10 months after implantation in canine bone. X-ray diffractometry, infrared analysis, transmission electron microscopy, and energy dispersive X-ray analysis were used. The dense HA is composed of crystal grains, with a well crystallized structure of HA, closely bound to each other and approximately 0.4-0.6 micron in size. Implantation did not change the original sintered structure of the dense HA. The HA coating was composed of an amorphous phase with a Ca/P ratio of 1.46 and a crystal phase consisting of oxyhydroxyapatite, tricalcium phosphate, tetracalcium phosphate, and CaO, with a Ca/P ratio of 1.57. In the amorphous phase, compared to other portions in the amorphous phase, there were some layers with lower atomic density and with no significant difference in Ca/P ratio. After implantation, the crystallization of super fine crystals of approximately 4-5 nm in thickness occurred in the amorphous phase, and with time it progressed and spread from the surface to the deeper portion of the HA coating. A Ca/P ratio of 1.58 in the crystallized portion was close to the ratio (1.60) in the dense HA, suggesting that the super fine crystals were HA. This crystallization cannot significantly decrease the solubility of the amorphous phase portion and poses risks of stress accumulation within the coating and a decrease of binding strength between the HA coating and the substrate.

The process of physical weakening and dissolution of the HA-coated implant in bone and soft tissue

Hydroxyapatite (HA)-coated implants were developed to promote osseointegration of titanium implants and to overcome the mechanical drawbacks of solid HA implants. Although many clinical reports on the prognosis of HA-coated implants have reported high success rates, the risks of dissolution and weakening of the coating have been noted. We hypothesized that the chemical and mechanical stability of HA coating are affected by its microstructural characteristics. The present study investigates differences in the microstructures of available HA-coated implants, before and after implantation into the coxal bones of dogs for periods ranging from 3 weeks to 10 months and under the coxal periosteum of dogs for 10 months. The results of transmission electron microscopy and energy-dispersive x-ray analysis revealed that crystallization of super-fine HA crystals occurred in the amorphous phase of the HA coating and progressed over time. This crystallization weakens HA-coated implants by making the amorphous phase brittle, causing stress accumulation within the coating, and causing a decrease in the binding strength between the coating and the substrate. Furthermore, the HA coating dissolved in soft tissue. Dissolution started with the super-fine HA crystals in the crystallized portion that was originally part of the amorphous phase.

Microstructural changes in bone of HA-coated implants

In our previous comparative push-out test of HA-coated implants and dense HA implants in dog bone, the ratio of the push-out value of the HA-coated implant to that of the dense HA implant decreased with time due to weakening of the HA coating as compared to the dense, more durable HA. The aim of this study was to investigate by histological examination of HA-coated implants in dog bone, using TEM, how this weakening of the HA coating occurs. The HA coating before implantation is composed of an amorphous glassy phase and a crystal phase scattered within the glassy phase. After implantation, the crystal phase remained almost unchanged. However, in the glassy phase, crystallization occurred and progressed with time. By 3 weeks after implantation, this crystallization already had started in the surface portion of the HA coating where it was covered by bone and also where it still touched the soft tissue. By 10 months, the crystallization had progressed to the deeper portion of the HA coating and had expanded to most of the glassy phase except for the narrow portions along the substrate-coating interface. These findings suggest that a progression of crystallization in the glassy phase causes stress accumulation within the HA coating, especially in the interface between the HA coating and the substrate, and that this stress accumulation results in a weakening of the HA-coated implant.