Surface Modification Technologies V - Proceedings of the Fifth International Conference Held in Birmingham, UK

909 Pages·1992·61.587 MB·909\909

by  Sudarshan, T. S., Braza, J. F.

SURFACE
MODIFICATION
TECHNOLOGIES
V
Proceedings of the Fifth International Conference
held in Birmingham, UK, 2-4 September 1991
Editors (Proceedings)
T.S. SUDARSHAN
Materials Modification Inc.
2929-P1 Eskridge Center
Merrifield, Fairfax
VA 22031, USA
J.F. BRAZA
The Torrington Company
59 Field Street, Torrington
CT 06790, USA
THE INSTITUTE OF MATERIALS
111999999222
Book No.529
Published1992by
The InstituteofMaterials
1CarltonHouse Terrace
LondonSWIY5DB
©The InstituteofMaterials1992
Allrightsreserved
British LibraryCataloguing-in-PublicationData
Available onrequest
LibraryofCongress Cataloging-in-PublicationData
Available on request
ConferenceSponsors
The InstituteofMetals
The Minerals, Metals andMaterialsSociety (TMS)
PrintedandboundinGreatBritainby
The UniversityPress, Cambridge
Contents
Foreword xi
0 ••••••••••••••••••••••••••• 0 • • • • •
Surface Modification Issues for Orthopaedic ImplantBearing
Surfaces 1
0 •••
J.A. DAVIDSON AND A.K. MISHRA
The Need for Improved OrthopaedicBearingSurfaces: A Clinical
Perspective. ................................................. 15
P. CAMPBELLAND H.C. AMSTUTZ
Generation ofDebris in TotalHip Replacements Due to Damage of
the Articulating Surfaces. ..................................... 25
D.L. BARTEL, F. BETTS, E.A. SALVATI, T.M. WRIGHT, C.M. RIMNAC,
J.-M. LEE AND S. DOTY
The Role ofPolymerParticles in the Process of AsepticLoosening
ofJoint Arthroplasties. ....................................... 35
S.B. GOODMAN
Human Bone Cell Proliferation and the Effects of Implant Wear
Debris: An In Vitro Study. .................................... 49
W.L. LANZER, J. A. DAVIDSON AND GoA. HOWARD
In Vivo and In Vitro WearBehaviourof Alumina Ceramic and
UHMWPE ImplantBearingSurfaces in TotalJoint Prostheses. .... 61
HIRONOBU OONISHI AND YU TAKAYAMA
Metallurgical and TribologicalModification of Titanium and
Titanium-based Alloys for Medical Devices by PlasmaAssisted
Techniques. ................................................. 77
BERNARD F. COLL, MARK A. PELLMAN,J.P. SOUCHARD AND
P. JACQUOT
AnodizedLayers on Titanium and TitaniumAlloy Orthopaedic
Materials for AntimicrobialActivity Applications .... 89
0 ••••••• 0 • • •
D.S. DUNN, S. RAGHAVAN AND R.G. VOLZ
In Vivo and In Vitro Wear Behaviouron WeightbearingSurfaces of
Polyethylene Sockets Improved by Irradiation inTotalHip
Prostheses 101
0 ••••••••••••••• 0 • • • • • • • • • • • • • • • • • • • • • • • ••
HIRONOBU OONISHI, YU TAKAYAMA AND EIJI TSUJI
Submicrometre Particulates inHumanPeriprostheticTissues. ...... 117
P. CAMPBELL, A. GELMAN, N. KOSSOVSKY AND H. AMSTUTZ
VI Surface Modification Technologies V
Tribologyof Alumina and Diamond-like Coatings for
OrthopaedicApplications ..................................... 125
E. WACHTEL, P. VILLARS, A. ARMINI AND M. SPECTOR
Wearof Ion-ImplantedPure Titanium and Ti-6AI-4VAlloy
Against UHMWPE........................................... 139
J. LAUSMAA,T. ROSTLUND AND H. McKELLOP
StructuralModifications Inducedby Ion Implantation in Metals and
Polymers used for OrthopaedicProstheses. ...................... 155
J. RIEU, A. PICHAT, L.-M. RABBE, A. RAMBERT, e. CHABROL AND
M.ROBELET
Ion-Surface Interactions: from Sputteringto Reactive Ion Etching.. 167
e. STEINBROCHEL
UniversalEnergy Dependence of Sputtering Yields at Low Ion
Energy..................................................... 187
c. STEINBROCHEL
SputterDeposition and In Situ Discharge Diagnostics ofTetragonal
and Amorphous BariumTitanate Grown on Unheated Substrates
Using Ar/0 and Ne/0 Discharges. ............................ 195
2 2
N.M. ABUHADBA AND c.a, AlTA
The Role ofTitanium Interlayers in the Adhesion ofTitanium
Nitride Thin Films. ........................................... 205
S.1. BULL AND P.R. CHALKER
CorrosionProperties of Single Layerand MultilayerPVD Coatings 217
O. KNOTEK, F. LOFFLER, A. SCHREY ANDJ.e. VERHOEF
Hydrogen Content of Chemical VapourDepositedDiamond. ...... 227
D.e. INGRAM AND M.L. LAKE
Application of Semiconducting DiamondFilms to Electronic
Devices. .................................................... 235
KEN OKANO,TATSUYA IWASAKI, HIDEO KIYOTA,
HIDEAKI MAEKAWA, TATEKI KUROSU AND MASAMORI IIDA
MechanicalProperties ofDiamondThin Films " 245
S.J. BULL, P.R. CHALKER AND C. JOHNSTON
Wear Characteristics and CuttingPerformance ofDiamond-Coated
Ceramic Tools. .............................................. 259
N. NARUTAKI, H. USUKI, Y. YAMANE AND T. ITO
n- and p-Type Dopingof Diamond: Past, Present and Future. ...... 273
J. BERNHOLC, S.A. KAJIHARA AND A. ANTONELLI
Surface Modification Technologies V vii
Ion BeamDeposition ofDiamond and Diamond-like Films , 283
W.M. LAU, S.-T. LEE AND QIN FUGUANG
Developmentof an Improved RF Plasma Ion Source to Grow
Diamond-Phase Thin Films. ................................... 301
Y. NAMBA, T. SAITOH AND E. HEIDARPOUR
PulsedLaser AblationProcess for Deposition of Diamond-Like
and otherSpecial Coatings .................................... 309
S.B. OGALE, A.P. MALSHE AND S.M. KANETKAR
Diamond-Like CarbonFabricationand Modification using Ion
Beams...................................................... 327
D.C. INGRAM
Flame Synthesis ofDiamond on Silicon ......................... 343
E.A. FREY,J.H.D. REBELLO AND V.V. SUBRAMANIAM
Analysis ofHydrogenated Carbon Films and SyntheticDiamond
Films... ... ... ... .. . . 357
A.G. FITZGERALD
LaserCladdingofPaste-boundHardfacingAlloys. ............... 371
E. LUGSCHEIDER, H. BOLENDER AND H. KRAPPITZ
A Comparison of the Properties of Coatings Produced byLaser
Cladding and ConventionalMethods. ........................... 383
E. LUGSCHEIDER AND B.C. OBERLANDER
ImprovedHigh Temperature Oxidation Resistance ofTi-6AI-4V
by Superficial LaserAlloying .................................. 401
A. GALERIE, A. FASASI, M. PONS AND M. CAILLET
LaserBeamInteractions of Group IV Elements. ................. 413
A. KASUYA AND Y. NISHINA
Deposition of Iron Oxide Based CoatingsbyPulsedExcimerLaser
Ablation. ................................................... 423
S. JOSHI AND S.B. OGALE
LaserProcessingofMaterialsfor Nuclear Applications. ........... 435
W. REITZ AND J. RAWERS
Surface Treatment ofAI-SiC Particle Compositeswith an Excimer
Laser.... .. .. 451
CHR. PANAGOPOULOS AND AL. MICHAELIDES
SurfaceModificationby MeansofLaserMelting Combinedwith
Shot Peening ................................................ 465
1. NOORDHUIS AND J. TH. M. DE HOSSON
viii Surface Modification Technologies V
A Relation BetweenLaserPower and InitialTemperature in Laser
Surface Treatments ofMetals. ................................. 475
A.M. DEUS, R. VILAR, O. CONDE AND J.S. FIGUEIRA
Surface Modification by Regular Arrangement of Microclusters on
the Surface of Graphite 491
0 •••••• 0 0 0 • • • • • ••
A. KASUYA, R. NISHITANI, N. HORIGUCHI AND Y. NISHINA
Chemically Deposited Bismuth Sulphide Thin Films for Solar
Energy Applications 503
0 0 ••••••• 0 ••• 0 ••••• 0 ••••••• 0 •••• 0 • ••
P.Ko NAIR AND M.T.S. NAIR
Cathode Voltage-Gas Composition-Film Crystallography
Relationships for Vanadia (VzOs) SputterDeposited in Ne/O,
Discharges 517
0 0 ••••• 0 0 •••••••••• 0 ••••••• 0 • • • • • • • • • ••
N.M. ABUHADBA AND C.R. AlTA
Modified SulphuricAcid Anodic Coatings for Spacecraft Thermal
Control 527
0 •••••• 0 •••••••••••••••••• 0 • • • • • • • • • • • • • • ••
HUONG G. LE, K.E. DAVID, C.A. SMITH AND D.L. O'BRIEN
Phase Maps for SputterDeposited Refractory Metal Oxide Ceramic
Coatings: A Review of Nb-Oxide, Y-Oxide, and Zr-Oxide Growth.. 541
C.R. AlTA
A Microstructural Study ofAluminide Surface Coatings on Single
CrystalNickel-Base Superalloy Substrates 557
'0' • • • • • • • • • • • • ••
W.F. GALE AND LE. KING
Comparison of Plasma Sprayed and Detonation Gun Sprayed
Alumina-Magnesia and Alumina-Titania Coatings .. 571
0 0 ••••••••• 0 0
K. NIEMI, P. VUORISTO, A. MAKELA, P. SORSA AND T. MANTYLA
Characteristics at High Temperature ofThin MetalFilms
Deposited on Ceramics .... 581
0 0 ••••••••• 0 •••••• 0 0 0 •••••• 0 • • • • • ••
NORIKO MORITA, MINORU KOBAYASHI AND HIDEYUKI KUWAHARA
Laser Gas Nitriding ofTitanium and Titanium Alloys ..... 593
0 •• 0 • • ••
P.H. MORTON, T. BELL, A. WEISHEIT, J. KROLL, BoL. MORDIKE
AND K. SAGOO
Effect of Additives in the Preparation ofPbOzDeposits on the
ElectrocatalyticActivity 611
0 •••••••• 0 • • • • ••
TEN-CHIN WEN AND CHIA-CHIN CHANG
CausticFlame Machining 619
0 •••••••• 0 ••••••• 0 •••••••••• 0
R. PERKINS AND R. AIREY
Surface Modification Technologies V ix
Recrystallization ofThin PolycrystallineSiliconFilms with aDual
Line Electron Beam. ......................................... 631
M. PAULI AND J. MOLLER
Iron-ZincAlloying Reaction on Interstitial-Free Steels. ........... 641
J. INAGAKI, M. MORITA AND M. SAGIYAMA
The Need for Standardizationin CoatingEvaluationTechniques 659
S.R.J. SAUNDERS AND S.J. BULL
Protection of Alloys Against High Temperature Sulphidation by
Si0 Coatings Deposited byMOCVD ...... 677
2
R. HOFMAN, J.G.F. WESTHEIM, T. FRANSEN AND P.J. GELLINGS
Aluminium Nitride asa CorrosionProtection Coating for Steel:
The Self-Sealing Porous Electrode Model. ...................... 691
W.S. TAIT AND C.R. AlTA
Influence of Composition and Processing Parameters on the
Mechanical Properties and Erosion Response of Ni+TiB Coatings 699
2
J.1. WERT AND S.J. OPPLIGER
Use ofThin Solid Films at Head/Magnetic Media Interfaces ....... 723
N.OHMAE,H.HARA,H.SEKIANDI.ENDO
Effects ofLaserSurface Cladding on Wear Behaviour of
Cobalt-Based Alloys. ......................................... 733
MING-CHANG JENG, LI-YUNG YAN AND JI-LIANG DOONG
SlidingWearEvaluation ofVarious Coating Precesses on
AISI 52100and M-50 Steel " 749
J.F. BRAZA
Compositional and Processing Effects on the Morphology,
Mechanical Properties and ErosionBehaviourofThin Intermetallic
Films. ...................................................... 765
E.R. PUKNYS, DRJ.J. WERT AND R.L. FREENEY
TheEffect of Coatings on the Rolling ContactFatigue Behaviourof
M50BearingSteel. ........................................... 785
R.M. MIDDLETON, P.J. HUANG, M.G.H. WELLS AND R.A. KANT
TribologicalBehaviourof Diamond and Diamond-like CarbonFilms:
Status and Prospects. ......................................... 801
J.F. BRAZA AND T.S. SUDARSHAN
TribologicalProperties ofLaserPolishedTiC Coatings on Graphite 821
A. BACHLI, A. BLATIER, M. MAILLAT AND H.E. HINTERMANN
x Surface Modification Technologies V
Tribological Behaviour of Silver Films Prepared on Ceramic
Surfaces by Ion Beam Assisted Deposition .. . . . . . . . . . . . . . . . . . . .. 835
A. ERDEMIR, R.A. ERCK, 0.0. AJAYI, J.H. HSIEH, C.C. CHENG
AND F.A. NICHOLS
Processing and Microstructural Studies of Electron
Beam-Processed Plasma-Sprayed AI, Cu and AI-Cu Coatings. . . . .. 853
F. BROSSA, F. DOS SANTOS MARQUES AND M. JEANDIN
Adhesive Properties of Hypersonic Sprayed Coatings of Chromium
Carbide and Tungsten Carbide on Steels . . . . . . . . . . . . . . . . . . . . . . .. 861
J. LESAGE AND G. MESMACQUE
Passivation of Surface States on InP with Sulphur Compounds 866
R.W.M. KWOK AND W.M. LAU
A Dual Mass-Separated Low-Energy Ion Beam System for Thin
Film Deposition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 873
QIN FUGUANG, WANG XIANGMING, LIU ZHIKAI, YAO ZHENYU,
REN ZHIZHANG, LIN LANYING, SU SHIJUN, JIANG WElSHING AND
W.M. LAU
Influence of Laser Cladding Parameters on the Microstructure and
Properties of Claddings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 881
E. LUGSCHEIDER, B.C. OBERLANDER AND S.E. LEISING
Index....................................................... 889
Index of Names. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 926
Surface Modification Issues for Orthopaedic Implant
Bearing Surfaces
l.A DAVIDSON, PhD and AK. MISHRA, PhD
OrthopaedicResearch Department, Smith and Nephew Richards Inc.,
1450Brooks Road, Memphis,TN 38116,USA
ABSTRACT
In total joint replacement, a polished metal surface generally articulates
against an ultrahigh molecular weight polyethylene (UHMWPE) counter
bearingsurface. Metals used include316Lstainless steel, Co-Cr-Mo alloy,
and Ti-6AI-4V alloy (particularly with a hardened N+ion implanted sur
face). Minimizing friction and UHMWPE wear is of prime concern for
long-termperformance. Additionally, it isdesirable to minimize metalion
release which results from constant removal and reformation of passive
surface oxides and oxyhydroxides during articulation. Long term effects
from the presence of potentially toxic or carcinogenic ions of Cr, Co, Mo,
Ni, V, and Al are not well known. This oxidative wear process can also
gradually increase the metal surface roughness and associated UHMWPE
wear, particularly for Ti-6AI-4V surfaces. Inert ceramic bearing surfaces
eliminatethisissue and are alsoresistantto potentialthree-bodywear from
bone cement debris or potential stray porous metal coating material.
However, ceramic (Alz03 and ZrOz)materials are available only for total
hip replacement. For total knee replacement, it istoo difficult and expen
sive to manufacture a monolithic ceramic knee surface, thus various sur
face coating methods are being investigated. These methods include
plasma sprayed Alz03 and ZrOz,TiN and amorphous diamond-like coat
ings via PVD/CVD methods, and in-situ oxidation. In other cases, the
existing metal surfaces are simply hardened using methods such as N+ion
implantation and oxygen or nitrogen diffusion hardening. This paper re
viewsthe limitations ofexisting totaljointsystems and the effectiveness of
various surface modification methods of orthopaedic implant bearing sur
faces on friction, oxidativewearand abrasion, UHMWPE wear, and metal
ion release.
SurfaceModificationTechnologiesV
EditedbyT.S.Sudarshanand J.F. Braza
TheInstituteofMaterials,1992
2 Surface Modification Technologies V
1. INTRODUCTION
There are numerous applications for surface modification techniques to
improve the long-term performance of orthopaedic implants. These
applicationsinclude modifying the surfaceoftotaljointreplacements,such
as the hip and knee (Fig. 1) with bioactive, osteogenic materials such as
calcium-phosphate ceramic layers, or with agents to address infection or
tissue reaction, or with treatments designed to improve the resistance of
the surface to potential fretting against bone or polymethylmethacrylate
(PMMA) bone cement. Modifications can also be used to alter the trib
ological performance of these implants: this is the subject of the present
Paper.
MINIMIZE MINIMIZEWEAR
METALION (CERAMIC)
Femur
RELEASE
(CERAMIC)
Patella
OPTIMUMSTABILITY r---;'-UHMWPE
(DESIGN,SURFACE
BIOACTIVECOATINGS)
Fig.1 Schematic illustrationoftotal hip and kneeimplants
Historically, 316L austenitic stainless steel, and to a greater degree,
Cobalt-Cr-Mo alloy (ASTM F-75 cast or wrought ASTM F-799) have
been used for articulation against polyethylene in total joint replacement
(Fig.1).Initially, inthelate1960s,polytetrafluorethylene (PTFE) wastried
as a polymeric bearingmaterial for total hip replacement. However, artic
ulation against 22mm diameterfemoral headsshowedexcessive and unac
ceptable wear rates. The PTFE was promptly replaced with high density
polyethylene (HDPE) and later, to further improve wear resistance, with
ultrahigh molecular weight polyethylene (UHMWPE), which is at present
the materialof choice.
The tribology of total joint replacement is extremely complex. Unlike
many tribological systems, total joint articulation exhibits extremely low
levels of wear and can function effectively for well over ten years. Al
though the cobalt alloy-UHMWPE wear pair is highly effective in mini
mizingwearand friction, furtherimprovementscan be madewith properly
designed ceramic-UHMWPE wear pairs. Many subtle tribological issues
are involved, and abetter understanding ofthese issues may allowfor still
further improvementsin totaljointarthroplasty via surface modification.