Abstract
Ceramic coatings on metallic implants are a promising alternative to conventional implants due to their ability to offer superior wear resistance. The present work investigates the sliding wear behavior under bovine serum solution and indentation crack growth resistance of four coatings, namely (1) conventional powder-derived alumina coating (Ap), (2) suspension-derived alumina coating (As), (3) composite Al2O3—20wt % Yittria stabilized Zirconia (YSZ) coating (AsYs) deposited using a mixed suspension, and (4) powder Al2O3—suspension YSZ hybrid composite coating ApYs developed by axial feeding plasma spraying, respectively. The indentation crack growth resistance of the hybrid coating was superior due to the inclusion of distributed fine YSZ particles along with coarser alumina splats. Enhanced wear resistance was observed for the powder derived Ap and the hybrid ApYs coatings, whereas the suspension sprayed As and AsYs coatings significantly deteriorated due to extensive pitting.
Highlights
Thermal spray technique is one of the most versatile surface engineering processes and enables the production of protective coatings, especially for harsh environments such as wear, corrosion/oxidation, high temperature, etc
The hydroxyapatite coating on the hip femoral stem is approved by the Food and Drug Administration (FDA) in the USA [3,4]
Plasma spraying involves the use of high energy plasma to transform the powder particles of the coating material into their molten state, and these are propelled towards the substrate to form a coating
Summary
Thermal spray technique is one of the most versatile surface engineering processes and enables the production of protective coatings, especially for harsh environments such as wear, corrosion/oxidation, high temperature, etc. Plasma spraying has an important role in orthopaedic implant application, where it is used to develop bio-ceramic (hydroxyapatite) coatings on the hip femoral stem to enhance Osseo-integration. The hydroxyapatite coating on the hip femoral stem is approved by the Food and Drug Administration (FDA) in the USA [3,4]. Plasma spraying involves the use of high energy plasma to transform the powder particles of the coating material into their molten state, and these are propelled towards the substrate to form a coating. Conventional plasma spraying uses a powder feedstock with a particle size distribution in the range of
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