Microplasma sprayed hydroxyapatite coatings

284 Pages·2013·31.064 MB·English

by  Arjun Dey, Anoop Kumar Mukhopadhyay

Materials Science M Microplasma Sprayed
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There has been enormous growth in the use of medical implants. However, oD
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in the case of hip replacement, loosening of metallic prosthesis fixed ady Hydroxyapatite Coatings
with polymethylmethylacrylate bone cement has resulted in painstaking h
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revision surgery, which is a major problem for the patient, surgeon, and y
biomedical technology itself. In fact, global recognition of this problem led
to the development of cementless fixation through the novel introduction
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of a bioactive hydroxyapatite (HAp) coating on biomedical-grade metallic
implants. Since then, a wide variety of coating methods have evolved to make i
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the HAp coatings on metallic implants more reliable. r
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Microplasma Sprayed Hydroxyapatite Coatings discusses plasma spraying
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and other related HAp coating techniques, focusing on the pros and cons
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of macroplasma sprayed (MAPS)- and microplasma sprayed (MIPS)-HAp
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coatings. The book begins by explaining what a biomaterial really is, what the
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frequently used term biocompatibility stands for, and why it is so important

for biomaterials to be biocompatible. It then: S
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• Examines the structural, chemical, macromechanical, micro/ a
nanomechanical, and tribological properties and residual stress y
of HAp coatings e
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• Evaluates the efficacies under simulated body fluid immersion for

H
MAPS- and MIPS-HAp coatings developed on biomedical implant-
grade SS316L substrates y
d
• Offers a comprehensive survey of state-of-the-art in vivo studies of
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MIPS-HAp coatings, presenting the results of pioneering research o
related to bone defect fixation x
y
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Shedding light on the future scope and possibilities of MIPS-HAp coatings,
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Microplasma Sprayed Hydroxyapatite Coatings provides a valuable ref- a
erence for students, researchers, and practitioners of biomedical engineering t
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and materials science. t
e

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Arjun Dey
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K23796
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6000 Broken Sound Parkway, NW
Suite 300, Boca Raton, FL 33487 ISBN: 978-1-4822-5093-0 s Anoop Kumar Mukhopadhyay
711 Third Avenue 90000
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K23796 cvr mech.indd 1 2/3/15 2:08 PM

Microplasma Sprayed
Hydroxyapatite Coatings

Microplasma Sprayed
Hydroxyapatite Coatings
Arjun Dey
Anoop Kumar Mukhopadhyay
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2015 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
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Version Date: 20150123
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To
Manju, Brishti, Tutum,
and
Omprita

Contents
Preface ...................................................................................................................xiii
Acknowledgments ..............................................................................................xxi
About the Authors .............................................................................................xxv
Common Abbreviations ...................................................................................xxix
1. Introduction .....................................................................................................1
1.1 Introduction of Biomaterials................................................................1
1.1.1 What Is a Biomaterial? .............................................................1
1.1.2 What Is Biocompatibility? .......................................................1
1.2 Types of Biomaterials ...........................................................................2
1.2.1 Incompatible and Biocompatible Materials ..........................2
1.2.2 Nearly Bioinert Materials........................................................3
1.2.3 Bioactive Materials ...................................................................3
1.3 Categories of Bioceramics ....................................................................3
1.4 What Is Hydroxyapatite?......................................................................4
1.5 What Is Hydroxyapatite Coating? ......................................................5
1.6 Introduction of Bone: A Natural Biomaterial ....................................7
1.7 Introduction of Teeth: A Natural Biomaterial ...................................9
1.8 Surface Engineering of Bioinert Materials ......................................10
1.9 Challenges to Develop Surface- Engineered Implants ...................12
1.10 Summary ..............................................................................................13
References .......................................................................................................13
2. Plasma Spraying and Other Related Coating Techniques ...................15
2.1 Plasma Spray Process .........................................................................15
2.2 How Will Coating Form? ...................................................................17
2.3 Plasma Sprayed HAp Coatings .........................................................17
2.4 Microplasma Spraying .......................................................................17
2.5 Microplasma Spraying and Its Application ....................................19
2.6 Microplasma Spraying: A Unique Manufacturing Technique .....22
2.7 Other Coating Processes ....................................................................24
2.7.1 High- Velocity Oxy Fuel .........................................................28
2.7.2 Pulsed Laser Deposition .......................................................28
2.7.3 Cold Spraying .........................................................................29
2.7.4 Liquid Precursor Plasma Spraying .....................................30
2.7.5 Electrophoretic Deposition ...................................................30
2.7.6 Electrohydrodynamic Atomization ....................................31
2.7.7 Sputtering................................................................................31
2.7.8 Sol- Gel and Dip Coating .......................................................33
2.7.9 Biomimetic Coating Process .................................................35
vii
viii Contents
2.8 Microplasma vs. Macroplasma Spraying ........................................35
2.9 Summary ..............................................................................................36
References .......................................................................................................37
3. Hydroxyapatite Coating and Its Application ..........................................43
3.1 Background of the Problem and Basic Issues .................................43
3.2 Applications of HAp Coating ............................................................44
3.3 HAp Coating Developed by Different Methods ............................44
3.3.1 Issues Related to High- Temperature Processes .................44
3.3.2 Issues Related to Low- Temperature Processes ..................45
3.3.3 Issues Related to MIPS Processes ........................................46
3.4 Microplasma and Macroplasma Sprayed HAp Coatings:
Pros and Cons ......................................................................................46
3.5 Influence of Plasma Spraying Parameters on HAp Coating ........47
3.5.1 Role of Plasma Spraying Atmosphere, Spraying
Current, and Stand- Off Distance .........................................47
3.5.2 Role of Gun Traverse Speed .................................................48
3.5.3 Role of Specimen Holder Arrangements ............................48
3.5.4 Macroplasma Spraying vs. Microplasma Spraying ..........49
3.6 Nanostructured HAp Coating ..........................................................49
3.7 HAp Composite Coating ....................................................................49
3.8 Plasma- Sprayed HAp Coating: Current Research Scenario .........50
3.8.1 Robot- Assisted Plasma Spraying .........................................50
3.8.2 Vacuum Plasma Spraying .....................................................50
3.8.3 Liquid Precursor Plasma Spraying .....................................51
3.8.4 Cold Spraying .........................................................................51
3.8.5 Microplasma Spraying ..........................................................51
3.9 Summary ..............................................................................................52
References .......................................................................................................53
4. Structural and Chemical Properties of Hydroxyapatite Coating .......59
4.1 Introduction .........................................................................................59
4.1.1 Thickness of HAp Coatings .................................................59
4.1.2 Porosity of HAp Coatings .....................................................61
4.1.3 Crystallinity of HAp Coatings .............................................62
4.2 Stoichiometry of HAp ........................................................................63
4.3 Phase Analysis of MIPS- HAp Coatings ..........................................64
4.4 Spectroscopic Investigation of MIPS- HAp Coatings .....................65
4.5 Microstructure of MIPS- HAp Coating ............................................66
4.5.1 As- Sprayed Condition ...........................................................66
4.5.2 Microstructure of MIPS- HAp Coatings in the
Polished Condition ................................................................69
4.5.3 Splat Geometry and Dimension ..........................................69
4.5.4 Analysis of Splat Formation .................................................71
4.5.5 Why Are Micropores Formed? ............................................73