Activity of plasma sprayed yttria stabilized zirconia reinforced hydroxyapatite/Ti–6Al–4V composite coatings in simulated body fluid

Advancements in incorporating metal ions onto the surface of biomedical titanium and its alloys via micro-arc oxidation: a research review

The incorporation of biologically active metallic elements into nano/micron-scale coatings through micro-arc oxidation (MAO) shows significant potential in enhancing the biological characteristics and functionality of titanium-based materials. By introducing diverse metal ions onto titanium implant surfaces, not only can their antibacterial, anti-inflammatory and corrosion resistance properties be heightened, but it also promotes vascular growth and facilitates the formation of new bone tissue. This review provides a thorough examination of recent advancements in this field, covering the characteristics of commonly used metal ions and their associated preparation parameters. It also highlights the diverse applications of specific metal ions in enhancing osteogenesis, angiogenesis, antibacterial efficacy, anti-inflammatory and corrosion resistance properties of titanium implants. Furthermore, the review discusses challenges faced and future prospects in this promising area of research. In conclusion, the synergistic approach of micro-arc oxidation and metal ion doping demonstrates substantial promise in advancing the effectiveness of biomedical titanium and its alloys, promising improved outcomes in medical implant applications.

The correlation between osseointegration and bonding strength at the bone-implant interface: In-vivo & ex-vivo investigations on hydroxyapatite and hydroxyapatite/titanium coatings

This study investigated the effects of hydroxyapatite (HA) and hydroxyapatite/titanium (HA/Ti) coatings on osseointegration and bonding strength at the bone-implant interface. The coatings were made using air plasma spray (APS), and three study groups were examined: 1) Uncoated commercial pure titanium (CP-Ti) rods; 2) HA-coated CP-Ti rods, and 3) Composite of 50 %wt HA + 50 %wt Ti coated CP-Ti rods. The rods were implanted into the distal femurs and proximal tibias of fifteen New Zealand white rabbits, and 8 weeks after the implantation, the samples were harvested. The results of pull-out tests showed that the ultimate strength of HA and HA/Ti coatings were significantly greater than the uncoated samples (P < 0.05). Moreover, even though the histological evaluations showed significantly greater osseointegration of HA/Ti composite coatings compared with HA coatings (P < 0.05), nonetheless, the composite of HA/Ti offers no significant increase in the ultimate strength, stiffness, and bonding strength at the bone-implant interface, compared with the HA group (P > 0.05). Thus, in an eight-week study, there was no linear correlation between the osseointegration and the bonding strength at the bone-implant interface. The results of this work may imply that the extent of osseointegration at the bone-implant interface does not necessarily determine the value of the bonding strength at the bone-implant interface. It is speculated that, in a longer-term study, a greater quality of bone formation may occur during osseointegration, between the implant and its adjacent bone, which can lead to a more enhanced bonding strength, compared with the 8-weeks post-surgery follow up.

Bioactive Surface Modifications through Thermally Sprayed Hydroxyapatite Composite Coatings: A Review over Selective Reinforcements

Hydroxyapatite (HA) has been an excellent replacement for the natural bone in orthopedic applications, owing to its close resemblance; however, it is brittle and has low strength. Surface modification techniques...

Comprehensive Survey on Nanobiomaterials for Bone Tissue Engineering Applications

One of the most important ideas ever produced by the application of materials science to the medical field is the notion of biomaterials. The nanostructured biomaterials play a crucial role in the development of new treatment strategies including not only the replacement of tissues and organs, but also repair and regeneration. They are designed to interact with damaged or injured tissues to induce regeneration, or as a forest for the production of laboratory tissues, so they must be micro-environmentally sensitive. The existing materials have many limitations, including impaired cell attachment, proliferation, and toxicity. Nanotechnology may open new avenues to bone tissue engineering by forming new assemblies similar in size and shape to the existing hierarchical bone structure. Organic and inorganic nanobiomaterials are increasingly used for bone tissue engineering applications because they may allow to overcome some of the current restrictions entailed by bone regeneration methods. This review covers the applications of different organic and inorganic nanobiomaterials in the field of hard tissue engineering.

Development of novel zirconia implant's materials gradated design with improved bioactive surface

Zirconia implants are becoming a preference choice for different applications such as knee, dental, among others. In order to improve osseointegration, implant's surfaces are usually coated with bioactive materials like hydroxyapatite (HAp) and beta-tricalcium phosphate (β-TCP) that are very similar to the calcium phosphates found in bones. However, due to the implantation process, these coatings can be detached from the zirconia surface, leading to implant premature failure. In this work, a new component materials design aiming to avoid this coating detachment problem is proposed. It is based on the use of a bioactive zirconia-calcium phosphate composite outer layer onto the zirconia bulk, where the zirconia bulk provides mechanical strength and the outer layer provides biological performance. In order to assess the potential of this new materials design, two types of bioactive zirconia outer composite layers (zirconia reinforced by 10 vol% of HAp and by 10 vol% of β-TCP) were produced by press and sinter process and the gradated samples were fully characterized concerning materials, mechanical resistance, fatigue resistance, and biological performance, as measured by different approaches. Results showed that the novel component materials design and the manufacturing process proposed for producing the bioactive zirconia samples with outer composite layers on zirconia bulk substrates are a promising solution for implants, with improved biological performance without substantially compromising their overall mechanical and fatigue properties.

Investigation the impact of ZTA addition on the properties of nano biogenic hydroxyapatite

The target of the recent study is to achieve a significant inexpensive and eco-friendly way for getting ZTA/HA composites, based on the nano-HA derived from the eggshell biogenic source. Combining simultaneously the porous structure; which is considered as a bone formation key, with developed mechanical properties and adequate biocompatibility, is another purpose of this study. Furthermore, the impact of ZTA addition from 10-30 mass-%, fabricated by uniaxial pressing and sintering at 1200-1300 °C for 2 h, on the physical and mechanical properties, microstructure and phase composition of ZTA/HA composite bodies was investigated. The results demonstrated that the increasing of ZTA content increases the bodies' apparent porosity and decreases the bulk density due to the decomposition of HA into β-TCP. Where the formation of β-TCP possessed the predominant impact on the mechanical properties of the sintered ZTA/HA composites. ICP, SEM, EDX and thin film XRD results of composites containing 20 mass-% ZTA affirmed the excellent bioactivity of the bodies.

An overview of chitin or chitosan/nano ceramic composite scaffolds for bone tissue engineering

Chitin and chitosan based nanocomposite scaffolds have been widely used for bone tissue engineering. These chitin and chitosan based scaffolds were reinforced with nanocomponents viz Hydroxyapatite (HAp), Bioglass ceramic (BGC), Silicon dioxide (SiO₂), Titanium dioxide (TiO₂) and Zirconium oxide (ZrO₂) to develop nanocomposite scaffolds. Plenty of works have been reported on the applications and characteristics of the nanoceramic composites however, compiling the work done in this field and presenting it in a single article is a thrust area. This review is written with an aim to fill this gap and focus on the preparations and applications of chitin or chitosan/nHAp, chitin or chitosan/nBGC, chitin or chitosan/nSiO₂, chitin or chitosan/nTiO₂ and chitin or chitosan/nZrO₂ in the field of bone tissue engineering in detail. Many reports so far exemplify the importance of ceramics in bone regeneration. The effect of nanoceramics over native ceramics in developing composites, its role in osteogenesis etc. are the gist of this review.

Surface Modifications and Their Effects on Titanium Dental Implants

This review covers several basic methodologies of surface treatment and their effects on titanium (Ti) implants. The importance of each treatment and its effects will be discussed in detail in order to compare their effectiveness in promoting osseointegration. Published literature for the last 18 years was selected with the use of keywords like titanium dental implant, surface roughness, coating, and osseointegration. Significant surface roughness played an important role in providing effective surface for bone implant contact, cell proliferation, and removal torque, despite having good mechanical properties. Overall, published studies indicated that an acid etched surface-modified and a coating application on commercial pure titanium implant was most preferable in producing the good surface roughness. Thus, a combination of a good surface roughness and mechanical properties of titanium could lead to successful dental implants.

Calcium Orthophosphate-Containing Biocomposites and Hybrid Biomaterials for Biomedical Applications

The state-of-the-art on calcium orthophosphate (CaPO4)-containing biocomposites and hybrid biomaterials suitable for biomedical applications is presented. Since these types of biomaterials offer many significant and exciting possibilities for hard tissue regeneration, this subject belongs to a rapidly expanding area of biomedical research. Through the successful combinations of the desired properties of matrix materials with those of fillers (in such systems, CaPO4 might play either role), innovative bone graft biomaterials can be designed. Various types of CaPO4-based biocomposites and hybrid biomaterials those are either already in use or being investigated for biomedical applications are extensively discussed. Many different formulations in terms of the material constituents, fabrication technologies, structural and bioactive properties, as well as both in vitro and in vivo characteristics have been already proposed. Among the others, the nano-structurally controlled biocomposites, those containing nanodimensional compounds, biomimetically fabricated formulations with collagen, chitin and/or gelatin, as well as various functionally graded structures seem to be the most promising candidates for clinical applications. The specific advantages of using CaPO4-based biocomposites and hybrid biomaterials in the selected applications are highlighted. As the way from a laboratory to a hospital is a long one and the prospective biomedical candidates have to meet many different necessities, the critical issues and scientific challenges that require further research and development are also examined.

Promoting bone-like apatite formation on titanium alloys through nanocrystalline tantalum nitride coatings

The study aims to advance the applicability of titanium alloys as bone implant materials by tackling some important aspects of surface robustness and bioactivity.

Engineering and functionalization of biomaterials via surface modification

Recent progress pertaining to the surface treatment of implantable macro-scale biomaterials and using micro- and nano-biomaterials for disease diagnosis and drug/gene delivery is reviewed.

Can anodised zirconium implants stimulate bone formation? Preliminary study in rat model

The mechanical properties and good biocompatibility of zirconium and some of its alloys make these materials good candidates for biomedical applications. The attractive in vivo performance of zirconium is mainly due to the presence of a protective oxide layer. In this preliminary study, the surface of pure zirconium modified by anodisation in acidic media at low potentials to enhance its barrier protection given by the oxides and osseointegration. Bare, commercially pure zirconium cylinders were compared to samples anodised at 30 V through electrochemical tests and scanning electron microscopy (SEM). For both conditions, in vivo tests were performed in a rat tibial osteotomy model. The histological features and fluorochrome-labelling changes of newly bone formed around the implants were evaluated on the non-decalcified sections 63 days after surgery. Electrochemical tests and SEM images show that the anodisation treatment increases the barrier effect over the material and the in vivo tests show continuous newly formed bone around the implant with a different amount of osteocytes in their lacunae depending on the region. There was no significant change in bone thickness around either kind of implant but the anodised samples had a significantly higher mineral apposition, suggesting that the anodisation treatment stimulates and assists the osseointegration process. We conclude that anodisation treatment at 30 V can stimulate the implant fixation in a rat model, making zirconium a strong candidate material for permanent implants.

Investigation on corrosion protection and mechanical performance of minerals substituted hydroxyapatite coating on HELCDEB-treated titanium using pulsed electrodeposition method

The present work aims to investigate the effects of mineral (strontium, magnesium and zinc) substituted hydroxyapatite (M-HAP) coating on high-energy low-current DC electron beam (HELCDEB)-treated titanium (Ti).

Bioactive bredigite coating with improved bonding strength, rapid apatite mineralization and excellent cytocompatibility

Previous studies have shown that bredigite (Ca7MgSi4O16) bioceramics possessed excellent biocompatibility, apatite-mineralization ability and mechanical properties. In this paper, the bredigite coating on Ti-6Al-4 V substrate was prepared by plasma spraying technique. The main compositions of the coating were bredigite crystal phase with small parts of amorphous phases. The bonding strength of the coating to Ti-6Al-4 V substrate reached 49.8 MPa, which was significantly higher than that of hydroxyapatite coating and other silicate-based bioceramic coatings prepared by same method. After immersed in simulated body fluid for 2 days, a distinct apatite layer was deposited on the surface of bredigite coating, indicating that the prepared bredigite coating has excellent apatite-mineralization ability. The prepared bredigite coating supported the attachment and proliferation of rabbit bone marrow stem cells. The proliferation level of bone marrow stem cells was significantly higher than that on the hydroxyapatite coating. Our further study showed that the released SiO44– and Mg2+ ions from bredigite coating as well as the formed nano-apatite layer on the coating surface might mainly contribute to the improvement of cell proliferation. The results indicated that the bredigite coating may be applied on orthopedic implants due to its excellent bonding strength, apatite mineralization and cytocompatibility.

Failure behavior of plasma-sprayed HAp coating on commercially pure titanium substrate in simulated body fluid (SBF) under bending load

Four point bending tests with acoustic emission (AE) monitoring were conducted for evaluating failure behavior of the plasma-sprayed hydroxyapatite (HAp) top coat on commercially pure titanium (cp-Ti) plate with and without mixed HAp/Ti bond coat. Effect of immersion in simulated body fluid (SBF) on failure behavior of the coated specimen was also investigated by immersing the specimen in SBF. The AE patterns obtained from the bending test of the HAp coating specimens after a week immersion in SBF clearly showed the earlier stage of delamination and spallation of the coating layer compared to those without immersion in SBF. It was also found that the bond coating improved failure resistance of the HAp coating specimen compared to that without the bond coat. Four point bend fatigue tests under ambient and SBF environments were also conducted with AE monitoring during the entire fatigue test for investigating the influence of SBF environment on fatigue failure behavior of the HAp coating specimen with the mixed HAp/Ti bond coat. The specimens tested at a stress amplitude of 120 MPa under both ambient and SBF environments could survive up to 10⁷ cycles without spallation of HAp coating layer. The specimens tested under SBF environment and those tested under ambient environment after immersion in SBF showed shorter fatigue life compared to those tested under ambient environment without SBF immersion. Micro-cracks nucleated in the coating layer in the early stage of fatigue life and then propagated into the cp-Ti substrate in the intermediate stage, which unstably propagated to failure in the final stage. It was found from the XRD analysis that the dissolution of the co-existing phases and the precipitation of the HAp phase were taken place during immersion in SBF. During this process, the co-existing phases disappeared from the coating layer and the HAp phase fully occupied the coating layer. The degradation of bending strength and fatigue life of the HAp coating specimens tested under SBF environment would be induced by dissolution of the co-existing phases from the coating layer during immersion in SBF.

Surface Modification of Pure Titanium by TiB Precipitation

Titanium and its alloys are common in medical implant applications because of their desirable properties, such as relatively low Young’s modulus, good fatigue strength, corrosion resistance, biocompatibility as well as formability and machinability. However, these materials cannot meet all of the clinical requirements. Current research focuses on improving not only the mechanical performance but mostly the biocompatibility of Ti-based systems through variations in alloy composition and surface treatment. One of the methods that allows the change of biological properties of Ti surface is the modification of its chemical composition. In this work plasma surface modification approach was used to improve mechanical properties by synthesis of composite layer structure on a pure titanium surface. The study aims at development of TiB precipitation dispersed uniformly at α-Ti matrix by plasma melting of Ti-2 wt% and Ti-10 wt% B alloy powders composition. Grain size of precursor powders obtained by mechanical alloying method and its homogenization can control the porosity and boron agglomeration tendency of the synthesized layers. Plasma procedure was taken under argon and helium inert atmosphere and surface was obtained by single passage of plasma pillar upon the prepared surface. The Vickers microhardness of obtained surface reached nearly 850HV, which was much higher compared with initial sample of the pure titanium substrate of 160HV. The surface corrosion resistance in 0.9% NaCl solution was nearly the same as for pure titanium, showing stable behaviour of created oxide layer, with no negative effect of dual phase microstructure.In vitrobiocompatibility test in static condition was performed. All samples showed good cell growth. Our studies suggests that chemical composition of modified titanium surface by TiB precipitation by plasma alloying process has no negative effect on cytocompatibility.

Biocomposites and hybrid biomaterials based on calcium orthophosphates

The state-of-the-art of biocomposites and hybrid biomaterials based on calcium orthophosphates that are suitable for biomedical applications is presented in this review. Since these types of biomaterials offer many significant and exciting possibilities for hard tissue regeneration, this subject belongs to a rapidly expanding area of biomedical research. Through successful combinations of the desired properties of matrix materials with those of fillers (in such systems, calcium orthophosphates might play either role), innovative bone graft biomaterials can be designed. Various types of biocomposites and hybrid biomaterials based on calcium orthophosphates, either those already in use or being investigated for biomedical applications, are extensively discussed. Many different formulations, in terms of the material constituents, fabrication technologies, structural and bioactive properties as well as both in vitro and in vivo characteristics, have already been proposed. Among the others, the nanostructurally controlled biocomposites, those containing nanodimensional compounds, biomimetically fabricated formulations with collagen, chitin and/or gelatin as well as various functionally graded structures seem to be the most promising candidates for clinical applications. The specific advantages of using biocomposites and hybrid biomaterials based on calcium orthophosphates in the selected applications are highlighted. As the way from the laboratory to the hospital is a long one, and the prospective biomedical candidates have to meet many different necessities, this review also examines the critical issues and scientific challenges that require further research and development.

In vitro dissolution of calcium phosphate-mullite composite in simulated body fluid

In our recent research, we have developed novel CaP-mullite composites for bone implant applications. In order to realize such applications, the in vitro dissolution behaviour of these materials needs to be evaluated. In this perspective, the present paper reports the dissolution behavior of pure hydroxyapatite (HAp) and hydroxyapatite composites with 20-30 wt% mullite in simulated body fluid (SBF). The in vitro dissolution experiments were carried out for different time duration starting from 7 days up to 28 days. XRD and SEM results show almost no dissolution for pure HAp and HAp composite with 30 wt% mullite. However, HAp-20 wt% mullite composite exhibits considerable dissolution after 7 days. The alpha-TCP phase mainly contributes to the dissolution process. Based on the dynamic changes in pH, ionic conductivity, Ca and P ion concentration in SBF as well as microstructural observations of the bioceramic surfaces after various time frames of immersion in SBF, the differences in dissolution behaviour are discussed.

Dental implant systems

Among various dental materials and their successful applications, a dental implant is a good example of the integrated system of science and technology involved in multiple disciplines including surface chemistry and physics, biomechanics, from macro-scale to nano-scale manufacturing technologies and surface engineering. As many other dental materials and devices, there are crucial requirements taken upon on dental implants systems, since surface of dental implants is directly in contact with vital hard/soft tissue and is subjected to chemical as well as mechanical bio-environments. Such requirements should, at least, include biological compatibility, mechanical compatibility, and morphological compatibility to surrounding vital tissues. In this review, based on carefully selected about 500 published articles, these requirements plus MRI compatibility are firstly reviewed, followed by surface texturing methods in details. Normally dental implants are placed to lost tooth/teeth location(s) in adult patients whose skeleton and bony growth have already completed. However, there are some controversial issues for placing dental implants in growing patients. This point has been, in most of dental articles, overlooked. This review, therefore, throws a deliberate sight on this point. Concluding this review, we are proposing a novel implant system that integrates materials science and up-dated surface technology to improve dental implant systems exhibiting bio- and mechano-functionalities.

Microstructure, bioactivity and osteoblast behavior of monoclinic zirconia coating with nanostructured surface

A monoclinic zirconia coating with a nanostructural surface was prepared on the Ti-6Al-4V substrate by an atmospheric plasma-spraying technique, and its microstructure and composition, as well as mechanical and biological properties, were investigated to explore potential application as a bioactive coating on bone implants. X-ray diffraction, transmission electron microscopy, scanning electron microscopy and Raman spectroscopy revealed that the zirconia coating was composed of monoclinic zirconia which was stable at low temperature, and its surface consists of nano-size grains 30-50 nm in size. The bond strength between the coating and the Ti-6Al-4V substrate was 48.4 + or - 6.1 MPa, which is higher than that of plasma-sprayed HA coatings. Hydrothermal experiments indicated that the coating was stable in a water environment and the phase composition and Vickers hardness were independent of the hydrothermal treatment time. Bone-like apatite is observed to precipitate on the surface of the coating after soaking in simulated body fluid for 6 days, indicating excellent bioactivity in vitro. The nanostructured surface composed of monoclinic zirconia is believed to be crucial to its bioactivity. Morphological observation and the cell proliferation test demonstrated that osteoblast-like MG63 cells could attach to, adhere to and proliferate well on the surface of the monoclinic zirconia coating, suggesting possible applications in hard tissue replacements.

Mechanical and in vitro biological performances of hydroxyapatite-carbon nanotube composite coatings deposited on Ti by aerosol deposition

Hydroxyapatite (HA)-carbon nanotube (CNT) composite coatings on Ti plate, produced by aerosol deposition using HA-CNT powders, were developed for biomedical applications. For the deposition process HA-CNT powder mixtures with CNT contents of 1 and 3 wt.% were used. Dense coatings with a thickness of 5 microm were fabricated, irrespective of the content of CNTs. No pores or microcracks were observed in the coatings. The coatings had good adhesion to the substrate, exhibiting a high adhesion strength, ranging from 27.3 to 29.0 MPa. Microstructural observation using field-emission gun scanning electron microscopy and transmission electron microscopy showed that CNTs with a typical tubular structure were found in the HA-CNT composite coatings. Nanoindentation tests revealed that the mechanical properties, such as the hardness and elastic modulus, were significantly improved by the addition of the CNTs to the HA coating. In addition, the proliferation and alkaline phosphatase (ALP) activity of MC3T3-E1 pre-osteoblast cells grown on the HA-CNT composite coatings were higher than those on the bare Ti and pure HA coating. The ALP activity of the composite coatings considerably improved as the CNT content increased. These results suggest that CNTs would be an effective reinforcing agent to enhance both the mechanical and biological performances of HA coatings.

A novel nano-porous alumina biomaterial with potential for loading with bioactive materials

Nano-porous alumina, with the potential for being loaded with bioactive materials, has been proposed as a novel material for coating implants. In this study, the shear strength of the interface between such nano-porous anodic aluminium oxide (AAO) coatings and titanium substrates, their biocompatibility, and their potential for pore loading have been investigated. An interface shear strength in excess of 29 MPa was obtained which is comparable with that of conventional plasma sprayed hydroxyapatite implant coatings. The viability and differentiation of MG63 osteoblastic cells co-cultured on the coating was found to be broadly comparable to that of similar cells co-cultured on conventional bioinert implant materials such as titanium and fully dense alumina. Extensive pore loading with silica nano-particles of different sizes and in different combinations was demonstrated throughout the thickness of AAO layers 1 microm and 60 microm thick. This work has demonstrated, that with suitable choice of pore filling materials, this novel coating might simultaneously combat infection, encourage bone regeneration, and secure fixation of the implant to bone.

Genetic effect of zirconium oxide coating on osteoblast-like cells

Zirconium is widely used as material for prosthetic devices because its good mechanical and chemical properties. When exposed to oxygen, zirconium becomes zirconium oxide (ZrO(2)), which is biocompatible. ZrO(2) can be also prepared as a colloidal suspension and then used to coat surfaces. Zirconium oxide coating (ZrO(2)C) can potentially have specific biologic effects, and among them is bone formation related to implant osseointegration. How this biomaterial alters osteoblast activity to promote bone formation is poorly understood. We therefore attempted to address this question by using microarray techniques to identify genes that are differently regulated in osteoblasts exposed to ZrO(2)C. By using DNA microarrays containing 20,000 genes, we identified in osteoblast-like cell lines (MG-63) cultured with ZrO(2)C several genes whose expression was significantly upregulated or downregulated. The differentially expressed genes cover a broad range of functional activities: (a) cell cycle regulation, (b) signal transduction, (c) immunity, and (d) cytoskeleton component. The data reported are, to our knowledge, the first genetic portrait of ZrO(2)C effects. They can be relevant to better understand the molecular mechanism of bone regeneration and as a model for comparing other materials with similar clinical effects.

In vitro dissolution of plasma-sprayed hydroxyapatite coatings with different characteristics: experimental study and modeling

The dissolution of plasma-sprayed hydroxyapatite (PHA) coatings with different characteristics, produced by various spraying conditions, in a Tris-buffered solution at pH 7.4 was experimentally studied through the measurement of the release of calcium ions. The phase composition of the coatings at surface and interface, and the porosity were evaluated. The analytical modeling revealed that the calcium dissolution process was composed of two stages. The first stage was found to be both surface and diffusion controlled. The second stage was an exactly diffusion-controlled dissolution. In the first stage, the rate of dissolution and the solubility of the coatings with minimum contents of impurity phases were mainly influenced by the contents of recrystallized HA (RHA) and amorphous calcium phosphate (ACP). It is suggested that the optimized values of the ACP and the RHA at the coating surface can tend to encourage the early fixation properties of the PHA coatings.

Nano-structural bioactive gradient coating fabricated by computer controlled plasma-spraying technology

The poor mechanical property of hydroxyapatite was the major problem for load bearing and implant coating in clinical applications. To overcome this weakness, a bioactive gradient coating with a special design composition of hydroxyapatite (HA), ZrO2, Ti, bioglass was developed. This 120 microm coating with an upper layer of 30-50 microm porous HA produced by computer controlled plasma spraying which maintained energy level of the plasma which ensure proper melting of powder. The crystal size of the coating was 18.6-26.2 nm. Transformation of t-ZrO2 to m-ZrO2 reduced the thermal stress that weakened the coating and lowered down interfacial strength of the coating and metal substrate. Thermal stress of sprayed coating was 16.4 MPa which was much smaller than the sample without thermal treatment of 67.1 MPa. Interfacial strength between the coating and metal substrate was 53 MPa which is much higher than conventional Hydroxyapatite coating. Based on XRD analysis crystallinity of HA approached 98%. Therefore, high temperature treatment improved long term stability of the coating through improved crystallinity of hydroxyapatite and reduced other impure calcium phosphate phase.

Biomimetic Ceramic Surfaces Produced by Thermal Spraying Nanostructured Titania: A Coating Alternative to Hydroxyapatite on Orthopedic Implants?

There is an ongoing effort to improve the quality and performance of orthopedic implants. Part of this work involves the development of coatings suitable for use in the human body and having properties and bio-performance characteristics better than those of existing materials. The present study focused on developing thermal spray titania coatings engineered to have a bimodal structure consisting of a major fraction of micron scale dimensions within which were dispersed zones of nanostructured material. The coatings were found to exhibit much stronger adhesion to Ti-6Al-4V substrates than conventional hydroxyapatite coatings and to possess excellent crack propagation resistance characteristics. Cell culture studies indicated that human osteoblasts attached and proliferated well on the coating surface. The surface nano-features and nanostructured zones in the coating are believed to play an important role in the improved bonding, mechanical properties and bio-performance.

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.