Fatigue behavior of calcium phosphate coatings with different stability under dry and wet conditions

There Are over 60 Ways to Produce Biocompatible Calcium Orthophosphate (CaPO4) Deposits on Various Substrates

A The present overview describes various production techniques for biocompatible calcium orthophosphate (abbreviated as CaPO4) deposits (coatings, films and layers) on the surfaces of various types of substrates to impart the biocompatible properties for artificial bone grafts. Since, after being implanted, the grafts always interact with the surrounding biological tissues at the interfaces, their surface properties are considered critical to clinical success. Due to the limited number of materials that can be tolerated in vivo, a new specialty of surface engineering has been developed to desirably modify any unacceptable material surface characteristics while maintaining the useful bulk performance. In 1975, the development of this approach led to the emergence of a special class of artificial bone grafts, in which various mechanically stable (and thus suitable for load-bearing applications) implantable biomaterials and artificial devices were coated with CaPO4. Since then, more than 7500 papers have been published on this subject and more than 500 new publications are added annually. In this review, a comprehensive analysis of the available literature has been performed with the main goal of finding as many deposition techniques as possible and more than 60 methods (double that if all known modifications are counted) for producing CaPO4 deposits on various substrates have been systematically described. Thus, besides the introduction, general knowledge and terminology, this review consists of two unequal parts. The first (bigger) part is a comprehensive summary of the known CaPO4 deposition techniques both currently used and discontinued/underdeveloped ones with brief descriptions of their major physical and chemical principles coupled with the key process parameters (when possible) to inform readers of their existence and remind them of the unused ones. The second (smaller) part includes fleeting essays on the most important properties and current biomedical applications of the CaPO4 deposits with an indication of possible future developments.

Calcium orthophosphate deposits: Preparation, properties and biomedical applications

Since various interactions among cells, surrounding tissues and implanted biomaterials always occur at their interfaces, the surface properties of potential implants appear to be of paramount importance for the clinical success. In view of the fact that a limited amount of materials appear to be tolerated by living organisms, a special discipline called surface engineering was developed to initiate the desirable changes to the exterior properties of various materials but still maintaining their useful bulk performances. In 1975, this approach resulted in the introduction of a special class of artificial bone grafts, composed of various mechanically stable (consequently, suitable for load bearing applications) implantable biomaterials and/or bio-devices covered by calcium orthophosphates (CaPO4) to both improve biocompatibility and provide an adequate bonding to the adjacent bones. Over 5000 publications on this topic were published since then. Therefore, a thorough analysis of the available literature has been performed and about 50 (this number is doubled, if all possible modifications are counted) deposition techniques of CaPO4 have been revealed, systematized and described. These CaPO4 deposits (coatings, films and layers) used to improve the surface properties of various types of artificial implants are the topic of this review.

Influence of substrate metal alloy type on the properties of hydroxyapatite coatings deposited using a novel ambient temperature deposition technique

Hydroxyapatite (HA) coatings are applied widely to enhance the level of osteointegration onto orthopedic implants. Atmospheric plasma spray (APS) is typically used for the deposition of these coatings; however, HA crystalline changes regularly occur during this high-thermal process. This article reports on the evaluation of a novel low-temperature (<47°C) HA deposition technique, called CoBlast, for the application of crystalline HA coatings. To-date, reports on the CoBlast technique have been limited to titanium alloy substrates. This study addresses the suitability of the CoBlast technique for the deposition of HA coatings on a number of alternative metal alloys utilized in the fabrication of orthopedic devices. In addition to titanium grade 5, both cobalt chromium and stainless steel 316 were investigated. In this study, HA coatings were deposited using both the CoBlast and the plasma sprayed techniques, and the resultant HA coating and substrate properties were evaluated and compared. The CoBlast-deposited HA coatings were found to present similar surface morphologies, interfacial properties, and composition irrespective of the substrate alloy type. Coating thickness however displayed some variation with the substrate alloy, ranging from 2.0 to 3.0 μm. This perhaps is associated with the electronegativity of the metal alloys. The APS-treated samples exhibited evidence of both coating, and significantly, substrate phase alterations for two metal alloys; titanium grade 5 and cobalt chrome. Conversely, the CoBlast-processed samples exhibited no phase changes in the substrates after depositions. The APS alterations were attributed to the brief, but high-intensity temperatures experienced during processing.

Contact nanofatigue shows crack growth in amorphous calcium phosphate on Ti, Co-Cr and Stainless steel

Fatigue testing of load-bearing coated implants is usually very time-consuming and so a new contact nanofatigue test using a nanoindenter has been evaluated. A cube corner indenter provided the fastest indication of failure, through crack formation, compared to a spherical indenter. Contact nanofatigue was performed on a sintered hydroxyapatite and then on amorphous calcium phosphate splats produced on titanium, stainless steel and Co-Cr surfaces, made either at room temperature or on 250°C preheated surfaces. Sintered hydroxyapatite showed continual plastic deformation, but this is not that apparent for splats on metal surfaces. Substrate preheating was found to induce cracking in splats, explained by greater thermal residual stresses. Endurance during contact nanofatigue, measured as time to crack formation, was the lowest for splats on titanium followed by Co-Cr and stainless steel. The splat on titanium showed both cracking and plastic deformation during testing. Good agreement has been reached with previous studies with cracking directed to the substrate without splat delamination. Contact nanofatigue with the nanoindenter easily and quickly identifies cracking events that previously required detection with acoustic emission, and shows good feasibility for mechanical testing of discs and splats produced by thermal spraying, spray forming, laser-ablation, aerosol jet and ink jet printing.

Biomimetic Apatite-coated PCL Scaffolds: Effect of Surface Nanotopography on Cellular Functions

In this study, polycaprolactone (PCL) scaffolds, consisting of agglomerated microspheres with nanotopographic surface structures, were fabricated by the freeze-drying method. These scaffolds were coated with bone-like apatite by using a calcium phosphate solution similar to saturated simulated body fluid (10× SBF-like) in two different immersion periods (6 and 24 h). Scanning electron microscopic views of the 6-h treatment in 10× SBF-like solution showed formation of calcium phosphate nucleation sites on the PCL scaffolds, while the apatite particles formed characteristic cauliflower-like morphology after 24 h. The X-ray diffraction (XRD) data showed that the mineral phase was made of hydroxyapatite (HA). The osteogenic activity of untreated and SBF-treated PCL scaffolds was examined by pre-osteoblastic MC3T3 cell culture studies. Cells had attached and spread on both the PCL scaffolds and the 6-h SBF immersion-treated scaffolds.

Characterization of functionally graded hydroxyapatite/titanium composite coatings plasma-sprayed on Ti alloys

Bioceramic coatings like hydroxyapatite (HA) have shown promising bioactive properties in load-bearing implant applications. The aim of this work is to deposit functionally graded HA/Ti layers consisting of an underlying Ti bond coat, the alternating layer, and an HA top-layer on Ti6Al4V substrates using plasma spray to improve the coating-substrate interface properties. The alternating layers were created by means of changing the feeding rate and input power of Ti and HA powders, which gradually decrease Ti content with increasing depth from the Ti bond-coat. The major consideration is to examine the stability of the graded coatings. Experimental results indicated that surface chemistry and morphology of the graded coatings were similar to those of monolithic HA coatings. The bond strength values of the as-sprayed graded coatings were much superior to those of monolithic HA coatings. The cyclic fatigue did have a statistically significant effect on bond strength of monolithic HA coatings, with a decrease of 23%. However, the graded coatings were able to survive 1 million cycles of loading in air without significantly reduced bond strength. The in vitro electrochemical measurement results also indicated that the graded coatings had a more beneficial and desired behavior than monolithic HA coatings after fatigue.

Mechanical properties of porous, electrosprayed calcium phosphate coatings

Mechanical properties of calcium phosphate coatings (CaP), deposited using the electrostatic spray deposition (ESD) technique, have been characterized using a range of analytical techniques, including tensile testing (ASTM C633), fatigue testing (ASTM E855), and scratch testing using blunt and sharp scratch styli. Moreover, a simple explantation procedure was successfully introduced using ESD-coated, threaded dental implants to characterize the mechanical performance of CaP coatings qualitatively under conditions that mimic clinical situations as close as possible. Generally, all analysis techniques revealed that ESD coatings need to be crystallized in order to ensure interfacial adhesion to the substrate and sufficient mechanical strength of the superficial reticular structure. Crystalline carbonated hydroxyapatite coatings (CHA, heat-treated at 700 degrees C) were resistant to fatigue as well as to plastic ploughing deformation by means of various scratch styli, and the fragile surface structure of ESD coatings was maintained to a large extent after unscrewing CHA-coated dental implants from femoral condyles of goat cadavers. From these experiments, it was concluded that interfacial adhesion of crystalline CHA ESD coatings to the titanium substrate was sufficient, but that mechanical strength of the superficial architecture of ESD coatings need to be optimized for applications where high shear and compressive stresses are imposed onto the rather fragile coating surface of reticular ESD morphologies.

Osteointegration of femoral stem prostheses with a bilayered calcium phosphate coating

Our purpose was to evaluate the osteointegration of bilayered calcium phosphate (CaP)-coated femoral hip stems in a canine model. A first layer of hydroxyapatite (HA) 20 microm thick and a superficial layer of Biphasic Calcium Phosphate (BCP) 30 microm thick were plasma-sprayed on to the proximal region of sandblasted Ti6Al4V prostheses. Bilayered CaP-coated and non-coated canine femoral stems were implanted bilaterally under general anesthesia in 6 adult female Beagle dogs. After 6 and 12 months, a significant degradation of the bilayered coating occurred with a remainder of 33.1+/-12.4 and 23.6+/-9.2 microm in thickness, respectively. Lamellar bone apposition was observed on bilayered coated implants while fibrous tissue encapsulation was observed on non-coated femoral stems. The bone-implant contacts (BIC) were 91+/-3% and 81+/-8% for coated and 7+/-8% and 8+/-12% for non-coated implants, at 6 and 12 months, respectively. Our study supports the concept of a direct relationship between the biodegradation of CaP coating and the enhanced osteointegration of titanium prostheses. A bilayered CaP coating might therefore enhance bone apposition in the early stages because of the superior bioactivity of the BCP layer while the more stable HA layer might sustain bone bonding over long periods.

Formation of apatite on poly(?-hydroxy acid) in an accelerated biomimetic process

Bonelike apatite coating was formed on poly(L-lactic acid) films and poly(glycolic acid) scaffolds within 24 h through an accelerated biomimetic process. The ion concentrations in the simulated body fluid (SBF) were nearly 5 times of those in the human blood plasma. The apatite formed was characterized by using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), and Fourier transform infrared spectroscopy (FTIR). The apatite formed in 5SBFs was similar in morphology and composition to that formed in the classical biomimetic process using SBF or 1.5SBF and similar to that of natural bone. This indicated that the biomimetic apatite-coating process could be accelerated by using concentrated simulated body fluid at 37 degrees C. Besides saving time, the accelerated biomimetic process is particularly significant to biodegradable polymers. Some polymers that degrade too fast to be coated with apatite by a classical biomimetic process (e.g., PGA) could be coated with bonelike apatite in an accelerated biomimetic process.

Patterning hydroxyapatite biocoating by electrophoretic deposition

Patterned bioceramic coatings may find potential applications in orthopedic implants and biosensors. In this study, various hydroxyapatite (HA) patterns were created on silicon and titanium substrates. Electrophoretic deposition technique was used together with surface patterning of the cathode specimen. When gold/palladium patterns (hexagons, spherical dots, etc.) were created on the cathode surface, HA colloidal particles in ethanol would preferentially deposit on the gold-coated area and form patterns. When silicon, instead of gold, was evaporated onto a conducting cathode surface, HA mainly deposited on the exposed area of the substrate. Detailed mechanisms for forming HA patterns may involve local concentration of the electric field when a second metal is patterned on the cathode. The difference in electric field across the two metals on the cathode also enhances HA patterning through an electrohydrodynamic process. This study demonstrated the possibility and flexibility of electrophoretic deposition in patterning charged particles onto a substrate.

Osteoblast differentiation of bone marrow stromal cells cultured on silica gel and sol-gel-derived titania

Primary cultures of osteogenic precursor cells derived from rat bone marrow stroma were performed on commercially available pure titanium discs (Ti c.p.) and surface modified Ti c.p.using a sol-gel technique (Ti sol). In separate repeated experimental runs, cell behavior and in vitro mineralization were compared with cultures on silica gel bioactive glass discs (S53P4). All substrates were incubated in simulated body fluid prior to the experiment. Overall, variable effects between experimental runs were seen. Apparently, this was due to the heterogeneous nature of the used cell population. Therefore, only careful conclusions can be made. Initial cell adhesion and growth rates between 3 and 5 days of culture--analyzed by cell numbers--were in general comparable for the two titanium substrates, while initial growth up to day 3 is suggested to be higher in Ti c.p. compared to Ti sol. Although initial cell adhesion on the S53P4 glass discs was lower than the titanium substrates, cell growth rates appeared to be higher on the silica gel compared to the two titanium substrates. Further, there were some indications that the early and late osteoblast differentiation markers, alkaline phosphatase and osteocalcin, monitored up to day 24, were elevated in Ti c.p cultures compared to Ti sol cultures. There were no differences observed in in vitro mineralization between the titanium groups. S53P4 seemed to display a substantially higher differentiating capacity for both osteogenic cell markers as well as in vitro mineralization compared to the two titanium substrates.

Formation of bone-like apatite on poly(L-lactic acid) fibers by a biomimetic process

Bone-like apatite coating on poly(L-lactic acid) (PLLA) fibers was formed by immersing the fibers in a modified simulated body fluid (SBF) at 37 degrees C and pH 7.3 after hydrolysis of the fibers in water. The ion concentrations in SBF were nearly 1.5 times of those in the human blood plasma. The apatite was characterized by scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDX), X-ray photoelectron spectroscopy (XPS), thin-film X-ray diffraction, and Fourier transform infrared spectroscopy. After 15 days of incubation in SBF, an apatite layer with about 5-6 microm thickness was formed on the surface of the fibers. This apatite had a Ca/P ratio similar to that of natural bone. The mass of apatite coated PLLA fibers increased with extending the incubation time. After 20 days incubation, the fibers increased their mass by 25.8 +/- 2.1%. The apatite coating had no significant effect on the tensile properties of PLLA fibers. In this article, the bone-like apatite coating on three-dimensional PLLA braids was also studied. The motivation for this apatite coating was that it might demonstrate enhanced osteoconductivity in the future studies when they serve as biodegradable scaffolds in tissue engineering.