Porous Coatings Research Articles

The Anti/Deicing Performance of the Low Interfacial Toughness Coating Is Enhanced: Induced Ice Crack Generation and Its Extension.

The low interfacial toughness of the material surface is important for crack initiation and expansion of the ice layer as it remains an effective method for large-scale deicing. However, there are challenges, such as a large critical icing size and incomplete shedding of the ice layer. Adjusting the interfacial forces to make the ice more prone to cracking, expanding, and shedding is advantageous in addressing the problem of anti-icing failure in materials with low interfacial toughness. Therefore, we propose a deicing strategy that combines porous PDMS (polydimethylsiloxane) coatings with low interfacial toughness and piezoelectric vibration. A series of hydrophobic porous PDMS coatings with different porosities were prepared on the surface of an aluminum alloy substrate through curing and phase separation. The elastic modulus of the coatings decreased from 1465 to 509 kPa as the coating porosity increased, revealing the mechanism behind the improvement in mechanical properties. The key to promoting ice fracture on porous PDMS coatings lies in the synergistic effect of the out-of-plane shear stress and microcracks at the solid-ice interface. This work focuses on exploring the characteristics of interfacial forces by combining the intrinsic mechanical properties of coatings with external forces, providing new insights for designing low interfacial toughness anti-icing materials.

Critical heat flux enhancement by porous coatings and prediction model development under External Reactor Vessel Cooling conditions

Critical heat flux (CHF) is the important limitation to estimate the effectiveness of the In-vessel retention (IVR) strategy for the severe accident mitigation. However, as the reactor power increases in the new-generation nuclear power plant, it is necessary to ensure the sufficient safety margin by taking some measures for the CHF enhancement. Porous coatings are recognized as an effective technique to improve the CHF. In this paper, the applicability of the porous coatings has been evaluated. The porous coatings consist of a dense layer and a porous layer. CHF experiments were constructed at the REPEC-III facility with 1:1 height ratio to the prototypic External Reactor Vessel Cooling (ERVC) environment. CHF on the porous surface is enhanced 32.4%–48.5 % under the ERVC conditions. Based on the experimental data, a mechanistic model considering the porous surface characteristics to predict CHF of the flow boiling under the ERVC natural circulation is developed and has a good predictive ability. The predicted CHF is compared with the experimental data of large-scale ERVC experiments. The mechanistic model can predict CHF within ±15 % error. Through the full-height experimental and theoretical analyses, porous coatings are an effective method to improve CHF and has a good application perspective for the IVR strategy in the nuclear power plant.

Effect of NaOH etching and oxygen plasma treatments on surface characteristics and their potential to activate micro-arc oxidized TiO2 coatings

Activation treatments such as NaOH etching or O2 plasma can play an essential role in surface conjugation of titanium with biomolecules, providing a better interaction at the bone-implant interface. However, their application on complex titanium dioxide (TiO2) surfaces is still not explored. In this contribution, bioactive and porous TiO2 coatings produced by micro-arc oxidation (MAO) were treated with NaOH etching or O2 plasma and then placed in contact with a reactive isocyanate test compound to evaluate the potential of molecule conjugation. Results suggested that O2 plasma treatment has only changed the surface chemistry of the coating through carbon contaminants removal, plasma-driven oxidation and generation of functional OH species, including reactive carboxyl groups. This chemical modification by plasma has made the surface superhydrophilic. After NaOH etching, the coating became rougher and also superhydrophilic, containing titanate structures doped with sodium and calcium on its surface and inside the inner pores. Upon reaction with butyl isocyanate, the O2 plasma-treated surfaces seem to better provide molecule conjugation, introducing characteristic conjugation bonds, and also making MAO coatings more hydrophobic due to the surface-terminated methyl chains from isocyanate. This proof-of-concept study has demonstrated the promising grafting potential given by O2 plasma on complex TiO2 surfaces.

A Customized Distribution of the Coefficient of Friction of the Porous Coating in the Short Femoral Stem Reduces Stress Shielding

Stress shielding and aseptic loosening have been identified as adverse effects of short-stem total hip arthroplasty resulting in hardware failure. However, there is a gap in research regarding the impact of stress shielding in customized porous coatings. The purpose of this study was to optimize the distribution of the coefficients of friction in the porous coating of a metaphyseal femoral stem to minimize stress shielding. Static structural analysis of an implanted short, tapered-wedge stem with a titanium porous coating was performed with the use of Analysis System Mechanical Software under axial loading. To limit computational time, we randomly sampled only 500 of the possible combinations of coefficients of friction. Results indicate that the coefficient of friction in the distal lateral porous coating significantly affected the mid-distal medial femoral surface and lateral femoral surface. The resultant increased proximal strains resulted from an increased coefficient of friction in lateral porous coating and a reduction in the coefficient of friction in medial mid-distal coating. These findings suggest that a customized porous coating distribution may produce strain patterns that are biomechanically closer to intact bone, thereby reducing stress shielding in short femoral stems.

Corrosion mechanisms of plasma sprayed porous coatings of Ni80Cr20 and alloy C-276 investigated by numerical and experimental method

Abstract: In this study, the corrosion performance of Ni80Cr20 and alloy C-276 (UNS N10276) coatings on 7075 aluminum alloy substrates was evaluated using a variety of performance characterization tests. Significant amounts of nickel oxide were found in the corrosion products of the two coatings that were stripped, with molybdenum in the two coatings that were not stripped effectively slowing down the corrosion rate. Both coatings selectively corrode Cr, where it is worth noting that the preferential corrosion of W elements in alloy C-276 has a positive effect on its surface protection. It is not only the amount of molybdenum content, but also the influence of the W element that leads to better corrosion resistance of alloy C-276 coating than Ni80Cr20 alloy coating. The coating spraying process due to process parameters and its own nature, etc. has caused different sizes of pores, while these pores in the corrosion process will have a certain degree of influence on the corrosion process. The size of the pore defects for the coating transverse corrosion effect was more significant, and small pore defects accelerated the corrosion process. The number of pore defects had a more significant effect on the longitudinal corrosion of the coating, and multiple pore defects slowed the corrosion process.

Organic-Inorganic Biocompatible Coatings for Temporary and Permanent Metal Implants.

The general trend of increasing life expectancy will consistently drive the demand for orthopedic prostheses. In addition to the elderly, the younger population is also in urgent need of orthopedic devices, as bone fractures are a relatively common injury type; it is important to treat the patient quickly, painlessly, and eliminate further health complications. In the field of traumatology and orthopedics, metals and their alloys are currently the most commonly used materials. In this context, numerous scientists are engaged in the search for new implant materials and coatings. Among the various coating techniques, plasma electrolytic oxidation (PEO) (or micro-arc oxidation-MAO) occupy a distinct position. This method offers a cost-effective and environmentally friendly approach to modification of metal surfaces. PEO can effectively form porous, corrosion-resistant, and bioactive coatings on light alloys. The porous oxide surface structure welcomes organic molecules that can significantly enhance the corrosion resistance of the implant and improve the biological response of the body. The review considers the most crucial aspects of new combined PEO-organic coatings on metal implants, in terms of their potential for implantation, corrosion resistance, and biological activity in vitro and in vivo.

High‐temperature thermal conductivity measurement of porous ceramic coatings with a high heat flux CO2 laser rig

AbstractYttrium‐stabilized zirconia (YSZ) plays a crucial role in thermal barrier coatings widely used to protect metallic components in gas turbine engines against high‐temperature combustion product gases and harsh environments. The thermal conductivity of these coatings is a critical parameter influencing the gas turbine design, performance, and service life. In this study, a laser temperature gradient method is utilized to measure the thermal conductivity of porous YSZ coatings. The method employs specialized laser energy delivery to create a one‐dimensional temperature gradient through the sample thickness, closely simulating the operational condition. This approach provides an effective, direct means to determine the thermal conductivity of high‐temperature heat‐resistant porous ceramic materials.

Environmental barrier coatings on alumina-reinforced CMCs: Experimental validation and numerical modeling of thermal stability

Recent advancements in ceramic matrix composites (CMCs), including SiC/SiC, C/SiC, C/C, Al2O3 reinforced Al2O3, face various challenges at high temperature applications, including grain growth, sintering, and creep deformation which are leading to strength loss. The new generation of Environmental Barrier Coatings (EBCs) must allow the protection of these CMCs when operating under harsh conditions, which can reach up to 1100 °C in some applications, such as gas turbines and certain reforming processes. In this work, 8 wt% yttria stabilized zirconia (8YSZ) applied by Atmospheric Plasma Spraying (APS) on top of a porous alumina oxide matrix with reinforced alumina fibers Al2O3/Al2O3-CMC (OCMC), considering different interfaces, has been studied. Surface morphology and pre-treatment of CMCs is the most challenging part for thermal spray applications. Hence, two different surface structure were used in this work. The results show that the roughness of OCMC can be reduced from Rz = 41.8±6.8 μm to 20.3±1.1 μm with the new porous bond coat and plasma sprayed coating, resulting in a homogeneous surface morphology.. In terms of thermal stability, a numerical model that combines Object Oriented FEM (OOF) and Cohesive Zone Model CZM tools, has been developed to evaluate the effect of the porosity of the real microstructure and the characteristics of the interfacial roughness profile, respectively, in CMC/EBC structures. In addition, other materials, such as La2Zr2O7 and Y2O3, have been numerically studied in order to evaluate their suitability as EBC.

Impact of atmospheric plasma spraying parameters on microstructure, mechanical properties and thermal cycling performance of YSZ coatings

Yttria-stabilized zirconia (YSZ) coatings are widely utilized thermal protective layers for metal and superalloy surfaces. These coatings are employed as thermal barrier coating (TBCs) to insulate metallic parts from higher thermal energy, thereby minimizing the cooling need for the topcoat ceramic layer. The choice of material is 7 wt% YSZ due to its exceptional capability to withstand challenging conditions characterized by extremely high temperatures and pressures, typically employed by the atmospheric plasma spraying (APS) in gas turbines, effectively extending their lifespan and improving performance. The deposition process of TBCs is significantly influenced by various spraying parameters, including gas flow rate and current (amp). These key parameters mutually play a significant role in controlling thermal stability, phase composition, and improved mechanical and microstructure properties. The aim of this research is to evaluate and contrast the impact of various spraying parameters on YSZ TBC performance. Accordingly, the influence of Hydrogen (H2), Argon (Ar) flow rate, and Current (amp) was investigated. Microstructure and elemental mapping studying was conducted using Field Emission Scanning Electron Microscopy FESEM/EDS and phase studying was examined with X-ray diffraction (XRD). Porosity was measured by IMAGE J software while hardness measurement was calculated by Vickers hardness tester. Additionally, thermal cycling tests were conducted between 700 °C and 1200 °C. The porous coatings exhibited poor performance, delaminating early during the tests. In contrast, dense coatings performed significantly better, enduring up to 140 cycles before failure.

Antibacterial cationic porous organic polymer coatings via an adsorption-contact-photodynamic inactivation strategy for treatment of drug-resistant bacteria

Although photodynamic therapy (PDT) has great potential for treating severely infected wounds, it is restricted by the short lifetime, limited diffusion distance of reactive oxygen species (ROS), and incomplete contact with bacteria. Herein, we report a novel nanosized ionic porous organic polymer (TPAPy-IPOP) based on the triphenylamine (TPA) moiety. Strong electron-deficient cationic groups were introduced into TPA to construct the donor–acceptor (D–A) system, in which the photoelectric effect of TPAPy-IPOP was greatly enhanced, and it was easily excited to produce ROS under irradiation with visible light. The introduction of cations not only facilitated bacterial adsorption by TPAPy-IPOP via electrostatic attraction, which was more conducive to killing bacteria by ROS, but also inactivated bacteria by the cations directly. The nanosized TPAPy-IPOP remained suspended in water for several months and could be sprayed onto various substrates to form a durable coating with excellent antibacterial properties. The in vivo results proved that the silk fibroin/polyvinyl alcohol non-woven fabric (SF/PVA) coated with TPAPy-IPOP could create and maintain a sterile microenvironment at a wound site. The rapid reduction in inflammation resulting from its bactericidal action accelerated the wound healing rate. Collectively, this design is expected to offer a generalizable approach for developing novel antibacterial therapeutic photosensitizers, especially for infected wound treatment.

Evaporation from thin porous Coatings: Pore size effects and predictive equation for homogeneous coatings

Evaporation of small water droplets on solids is hindered because surface tension pulls the droplet into a spherical cap that has a small perimeter. Our solution is to coat a solid with a very thin, porous layer into which the droplet flows to create a large-area disk with concomitant high rate of evaporation. We investigate evaporation by varying factors that have not been previously considered: pore size and distribution, contact angle, temperature, and relative humidity (RH).A larger pore size resulted in faster evaporation, which we explain through faster transport within the coating. Even faster evaporation occurred for a bilayer structure with small particles on the air side and larger particles on the solid side. The water advancing contact angle had an insignificant effect in the range from < 10° through to 60°.Our results for different pore sizes, temperature, humidity, and contact angle all collapse onto a single curve when appropriately normalized. This validates an equation that can be used for the evaporation from a homogeneous coating that depends only one empirical factor and the droplet volume. Since the volume is often user-controlled, we envisage that this equation can be used to predict evaporation and guide design of fast-drying coatings.

Micro-arc driven porous ZrO2 coating for tailoring surface properties of titanium for dental implants application

Titanium (Ti) is an ideal material for dental implants due to its excellent properties. However, corrosion and mechanical wear lead to Ti ions and particles release, triggering inflammatory responses and bone resorption. To overcome these challenges, surface modification techniques are used, including micro-arc oxidation (MAO). MAO creates adherent, porous coatings on Ti implants with diverse chemical compositions. In this context, zirconia element stands out in its wear and corrosion properties associated with low friction and chemical stability. Therefore, we investigated the impact of adding zirconium oxide (ZrO2) to Ti surfaces through MAO, aiming for improved electrochemical and mechanical properties. Additionally, the antimicrobial and modulatory potentials, cytocompatibility, and proteomic profile of surfaces were investigated. Ti discs were divided into four groups: machined – control (cpTi), treated by MAO with 0.04 M KOH – control (KOH), and two experimental groups incorporating ZrO2 at concentrations of 0.04 M and 0.08 M, composing the KOH@Zr4 and KOH@Zr8 groups. KOH@Zr8 showed higher surface porosity and roughness, even distribution of zirconia, formation of crystalline phases like ZrTiO4, and hydrophilicity. ZrO2 groups showed better mechanical performance including higher hardness values, lower wear area and mass loss, and higher friction coefficient under tribological conditions. The formation of a more compact oxide layer was observed, which favors the electrochemical stability of ZrO2 surfaces. Besides not inducing greater biofilm formation, ZrO2 surfaces reduced the load of pathogenic bacteria evidenced by the DNA-DNA checkerboard analysis. ZrO2 surfaces were cytocompatible with pre-osteoblastic cells. The saliva proteomic profile, evaluated by liquid chromatography coupled with tandem mass spectrometry, was slightly changed by zirconia, with more proteins adsorbed. KOH@Zr8 group notably absorbed proteins crucial for implant biological responses, like albumin and fibronectin. Incorporating ZrO2 improved the mechanical and electrochemical behavior of Ti surfaces, as well as modulated biofilm composition and provided suitable biological responses.

Passive control of porous media on the aerodynamic forces and wake structures of wall-mounted short circular cylinders

This paper numerically investigates the aerodynamic forces and the three-dimensional wake characteristics of wall-mounted circular cylinders with and without porous media coatings using large eddy simulation at a Reynolds number of 3.2×104. Short cylinders with aspect ratios of 0.5, 1.0, and 3.0 are considered, with one end fixed to a bottom wall in the current work. The study focuses on aerodynamic coefficients, flow characteristics, and wake structures for cylinders both with and without porous coatings. The statistical results indicate that porous media significantly alter flow patterns behind the cylinders, suppress downwash flow from the free end, and reduce velocity fluctuations and turbulent kinetic energy within the wake. The porous coating enhances the leeward side's base pressure, leading to a reduction in drag on the cylinder surface. The analysis of flow structures reveals that the topology of the arch vortex behind solid cylinders is significantly dependent on the aspect ratio, whereas this dependency is negligible for porous cylinders. Porous coatings diminish the intensity of the tip and trailing vortices behind the cylinder. Finally, based on the time-averaged flow field, we proposed two conceptual models of topological correlation for wall-mounted short cylinders, both with and without porous coatings, which contributes to describing the geometric characteristics and interactions of vortex structures.

Preparation of porous composite coatings to suppress surface charge movement and reduce electrical resistivity

In this work, Cr2O3/TiO2 composite coatings were prepared on α-Al2O3 insulating ceramic matrix surface by screen printing and solid phase sintering methods to yield an average film thickness of about 14.10 μm. Scanning electron microscopy (SEM) revealed changes in the pore structures of the coatings at different TiO2 contents. The atomic force microscopy (AFM) analysis of the coating surface roughness suggested a TiO2 content of 0.025 mol to yield the best surface roughness and pore structure of the coating. The calculation showed an increase in the energy level of the deep trap center on the surface from 1.506 eV to 1.547 eV, reaching a maximum. The surface resistivity of insulating ceramics decreased from 1016 Ω to 1012 Ω. The formation of deep surface traps and the decrease in surface resistivity promoted charge dispersion and suppressed the formation of flashover channels, effectively improving the surface flashover voltage of the ceramics.

A targeted vacuum-expansion sealing strategy for long-term protection of porous coatings

While surface treatments like anodic oxidation or micro-arc oxidation (MAO) significantly enhance the surface hardness and abrasion resistance of aluminum alloys, they often leave numerous dense pores or defects that compromise their corrosion resistance. Traditional sealing methods, such as boiling water or silane treatments, frequently fail to completely seal these micro-cavities and can introduce new defects due to volumetric shrinkage of the sealants, thereby reducing the service lifespan of the coatings. In this study, we introduce a novel vacuum-expansion sealing (VE sealing) strategy aimed at providing a more effective and durable sealing treatment. This method involves filling sealants in a vacuum environment, followed by volume expansion through ring-opening polymerization. Using this approach, the porosity of the porous MAO layer is significantly reduced, with the MAO-Ves coating porosity decreasing from 8.69 % to a remarkable 0.03 %. Electrochemical tests further demonstrate that after VE sealing, the sealed MAO sample maintains a higher low-frequency impedance |Z|0.01Hz of 1.16 × 107 Ω·cm2 after 672 h. This study not only presents a valuable strategy for enhancing the corrosion resistance of MAO coating, but also provides an efficient solution for improving the hardness, abrasion-resistance, and corrosion-resistance of surface-treated aluminum alloys and magnesium alloys.

A bioinspired hierarchical gradient structure to maximize resilience and enhanced cooling performance in polymeric radiative cooling coatings

Despite the extensive advancements in recent years, polymeric daytime radiative cooling (PDRC) coatings face certain challenges, encompassing restricted spectral performance, susceptibility to aging, poor mechanical strength, and so forth. Herein, we proposed a facile biomimetic 500 μm thick PDRC coating, featuring a gradient distribution of pore sizes throughout the cross-section. The proposed functional structure demonstrates spectral characteristics of a near-ideal broadband emitter by attaining over 0.95 emissivity in the main atmospheric window and 0.99 reflectance in the visible spectrum. During the outdoor experiment, it achieved an 8.5 °C subambient temperature drop along with a cooling power of ∼106 W/m2 at the solar irradiance of ∼800 W/m2 and ∼650 W/m2, respectively. Experimental findings highlight that the bioinspired design results in a tensile strength of ∼9 MPa along with a tensile strain of over 200%, which is more than twice that of non-gradient porous PDRC coatings. In addition, it offers tunable surface contact angle and manifests its resilience in anti-ultraviolet and water resistance tests. Furthermore, a building energy model reveals a decrease in cooling load of between 34 and 119 kWh/(m2.year), establishing its real-world application under broader climatic regions.

Microstructural Characterization of Porous Transport Layer Coatings

The porous transport layer (PTL) is a key component in polymer electrolyte membrane (PEM) water electrolyzers and serves the role of controlling the transport of reactants and products to and from the anode. Maintaining a low interfacial contact resistance between the titanium (Ti) fiber or sinter PTL and the iridium (Ir) anode catalyst is critical to maintaining the performance of the electrolyzer cell. This requires costly precious metal coatings, typically Pt, to inhibit the formation of native oxide layers during long-term cell operation. Strategies to reducing the thickness of these costly coatings including surface treatments, such as etching and abrasion, alternative low-cost coating materials, and implementation of microporous layers. It is crucial to understanding the morphologies and degradation mechanisms of these new strategies in order to accelerate the development of cheaper, more robust PTL coatings.In this work, correlative ex situ characterization methods, including laser confocal microscopy (LCM), focused ion beam (FIB), scanning electron microscopy (SEM), time-of-flight secondary ion mass spectrometry (ToF-SIMS), atomic force microscopy (AFM), X-ray photoelectron spectroscopy (XPS) and scanning transmission electron microscopy (STEM), are utilized to explore the impact surface treatments, such as etching and abrasion, on the Pt coatings uniformity and surface roughness. The thickness, local topography, and continuity of the Pt coating were quantified and correlated with interfacial contact resistance and electrochemical cell performance measurements. Changes to the thickness and composition of the coatings and oxide layers after single-cell tests will also be reported. Overall, these findings aim to guide the development of PTL treatments and coatings, ensuring the creation of highly durable and efficient PEM water electrolyzers that align with the U.S. Department of Energy's Hydrogen Shot goal of reducing the cost of clean hydrogen production to $1 per kilogram by 2031.Funding for this work was provided by U.S. Department of Energy Office of Energy Efficiency and Renewable Energy, Hydrogen and Fuel Cell Technologies Office through the H2NEW Consortium. Electron microscopy research conducted as part of a user project at the Center for Nanophase Materials Sciences (CNMS), which is a US Department of Energy, Office of Science User Facility at Oak Ridge National Laboratory.

Transparent metal oxide-based robust, porous, and thin polyurethane coatings for IR, and UV blocking and photocleaning terylene textiles

IR radiations from the sun increases the internal temperature of the buildings when transmitted through glass windows. To reduce this elevated temperature, air conditioning systems are used that consume a large share of total energy expenditure which harms the energy footprints of the ecosystem. To combat this problem IR radiation must be blocked, thereby not affecting visible light transmission. Conductive metal oxides have been found effective in blocking IR radiation. In this work, antimony-doped tin oxide sub-20 nm particles were synthesized by co-precipitation method. The synthesized nanoparticles were homogenously dispersed within polyurethane latex that later encrusted onto polyester textiles for IR-blocking properties. The coated fabrics simultaneously achieve excellent shielding of NIR (90 %) and high transmittance of visible light (80 %), which makes them an ideal material to alleviate the current building energy consumption issues that correspond to a greater than 20 % saving on indoor cooling/heating. These fabrics equally bear other special features such as strength, self-cleaning, and photoactivity required by such furnishing clothes. The developed IR blocking fabric will ensure a sustainable future with a less adverse load on the energy footprints of the ecosystem and thus make human settlements resilient and tackle the impacts of climate change.

CHF enhancements of flame-sprayed porous coatings on the outer surface of reactor pressure vessel bottom head

Considering the urgent need for enhancing critical heat flux (CHF) on the outer surface of the reactor pressure vessel (RPV) by in-vessel retention (IVR) on Generation III pressurized water reactors (PWRs), we prepare a porous coating of 316 L stainless steel on the surface of SA508 Grade 3 (SA508–3) steel by flame spraying in this study. Using a small-scale pool boiling experimental setup, we first investigate boiling heat transfer characteristics on bare surfaces and flame-sprayed porous coating surfaces of SA508–3 steel in deionized water at atmospheric pressure, and obtain pool boiling curves and CHFs at different inclination angles. Furthermore, we carry out the IVR engineering verification tests for a full-height RPV bottom head on the REPEC-II test facility built at Shanghai Jiao Tong University. Our experimental results demonstrate that the flame-sprayed porous coatings can significantly enhance the CHF by 21–50 % at different inclination angles of the RPV bottom head. Our full-height facility tests demonstrate that the CHF in the high-inclination angle region, which normally has very high heat flux due to the focusing effect, exceeds 2 MW/m2 on the flame-sprayed porous coating surface. Therefore, our flame-sprayed porous coating has the potential to improve the safety margin of RPV.

Debonding of Porous Coating: A Late Failure Mode of Uncemented, Partially Threaded Acetabular Components—Retrieval Analysis

Titanium plasma-sprayed (TPS) porous coatings have been used in total hip arthroplasty for decades. They are considered reliable, and very few failure cases have been described so far. This retrieval study described a series of 20 acetabular components—where total or partial debonding occurred during in vivo use and aimed to explain the underlying failure mechanisms. Implants were examined using optical and electron microscopy (SEM), metallographic sections of retrievals were prepared while pathologic samples of periprosthetic tissues were examined for presence of wear debris. Data from metallographic slides indicated that debonding was initiated at free borders of the coating and tended to progress at the interface between the TPS layer and the shell. In some cases, total debonding occurred leading material wear of both the TPS layer and acetabular shell leading to massive release of metallic debris and accelerated polyethylene wear in third body mechanism. SEM examination demonstrated that splats forming the TPS layer exhibited features suggesting a high temperature gradient between the plasma sprayed layer and the substrate material existed, leading to porosity of splats and suboptimal bonding strength. This study demonstrated that coating application parameters and certain design features (screw holes, fins) may promote long-term failure due to debonding. Surgeons should be aware of this complication as it is most likely underreported, while manufacturers should consider more rigorous pre-clinical testing as suboptimal coating bonding may result in failures during long-term clinical use.