Adhesion of thermally sprayed hydroxyapatite-bond-coat systems measured by a novel peel test.

Ti6Al4V foils, 100 microm thick, were coated with thin (10-15 microm) bond coats based on titania and zirconia, and subsequently coated with a thick (100-120 microm) hydroxyapatite layer, using atmospheric plasma spraying. Peel adhesion tests of the coating systems performed on the foils showed that titania, and mixed titania/non-stabilized zirconia bond coats improved the adhesion of the ceramic layers to the metallic substrate in a statistically significant way, while a partially CaO-stabilized zirconia bond coat led to a decrease of the peel adhesion strength when compared to hydroxyapatite coatings without a bond coat.

Microstructural and in vitro chemical investigations into plasma-sprayed bioceramic coatings.

Hydroxyapatite (HA) coatings plasma sprayed without and with bond coats (titania, zirconia) onto titanium alloy (Ti6A14V) substrates under both atmospheric and low pressure plasma spray conditions were investigated in terms of their microstructure and their resorption resistance during immersion in simulated body fluid (Hank's balanced salt solution). The microstructures of test samples were characterized using SEM on as-sprayed and leached surfaces and on the corresponding cross sections. Selected coating systems were studied by 2-dimensional secondary ion mass spectroscopy imaging to obtain information on plasma spray induced diffusional processes at the coating interfaces, as well as the spatial distribution of minor and trace elements.

Development of plasma-sprayed bioceramic coatings with bond coats based on titania and zirconia.

Bond coats for plasma-sprayed hydroxyapatite (HAp) coatings on Ti-6A1-4V hip endoprotheses are being developed for improved in vivo performance. Bond coat powders consisting of (i) CaO-stabilized zirconia, (ii) a eutectic composition of titania and non-stabilized zirconia, and (iii) titania were applied by atmospheric plasma spraying (APS) to Ti-6A1-4V-coupons and 100 microm-thick Ti-6A1-4V foils. Subsequently, a thick layer of HAp was sprayed onto the thin bond coats.