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Sample records for plasma-sprayed hydroxyapatite coatings

  1. Plasma Sprayed Hydroxyapatite Coatings: Influence of Spraying Power on Microstructure

    SciTech Connect

    Mohd, S. M.; Abd, M. Z.; Abd, A. N.

    2010-03-11

    The plasma sprayed hydroxyapatite (HA) coatings are used on metallic implants to enhance the bonding between the implant and bone in human body. The coating process was implemented at different spraying power for each spraying condition. The coatings formed from a rapid solidification of molten and partly molten particles that impact on the surface of substrate at high velocity and high temperature. The study was concentrated on different spraying power that is between 23 to 31 kW. The effect of different power on the coatings microstructure was investigated using scanning electron microscope (SEM) and phase composition was evaluated using X-ray diffraction (XRD) analysis. The coatings surface morphology showed distribution of molten, partially melted particles and some micro-cracks. The produced coatings were found to be porous as observed from the cross-sectional morphology. The coatings XRD results indicated the presence of crystalline phase of HA and each of the patterns was similar to the initial powder. Regardless of different spraying power, all the coatings were having similar XRD patterns.

  2. Direct morphological comparison of vacuum plasma sprayed and detonation gun sprayed hydroxyapatite coatings for orthopaedic applications.

    PubMed

    Gledhill, H C; Turner, I G; Doyle, C

    1999-02-01

    Hydroxyapatite coatings on titanium substrates were produced using two thermal spray techniques vacuum plasma spraying and detonation gun spraying. X-ray diffraction was used to compare crystallinity and residual stresses in the coatings. Porosity was measured using optical microscopy in conjunction with an image analysis system. Scanning electron microscopy and surface roughness measurements were used to characterise the surface morphologies of the coatings. The vacuum plasma sprayed coatings were found to have a lower residual stress, a higher crystallinity and a higher level of porosity than the detonation gun coatings. It is concluded that consideration needs to be given to the significance of such variations within the clinical context.

  3. Comparison of Physical-chemical and Mechanical Properties of Chlorapatite and Hydroxyapatite Plasma Sprayed Coatings

    PubMed Central

    Demnati, Imane; Grossin, David; Marsan, Olivier; Bertrand, Ghislaine; Collonges, Gérard; Combes, Christèle; Parco, Maria; Braceras, Inigo; Alexis, Joel; Balcaen, Yannick; Rey, Christian

    2015-01-01

    Chlorapatite can be considered a potential biomaterial for orthopaedic applications. Its use as plasma-sprayed coating could be of interest considering its thermal properties and particularly its ability to melt without decomposition unlike hydroxyapatite. Chlorapatite (ClA) was synthesized by a high-temperature ion exchange reaction starting from commercial stoichiometric hydroxyapatites (HA). The ClA powder showed similar characteristics as the original industrial HA powder, and was obtained in the monoclinic form. The HA and ClA powders were plasma-sprayed using a low-energy plasma spraying system with identical processing parameters. The coatings were characterized by physical-chemical methods, i.e. X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR) and Raman spectroscopy, including distribution mapping of the main phases detected such as amorphous calcium phosphate (ACP), oxyapatite (OA), and HA or ClA. The unexpected formation of oxyapatite in ClA coatings was assigned to a side reaction with contaminating oxygenated species (O2, H2O). ClA coatings exhibited characteristics different from HA, showing a lower content of oxyapatite and amorphous phase. Although their adhesion strength was found to be lower than that of HA coatings, their application could be an interesting alternative, offering, in particular, a larger range of spraying conditions without formation of massive impurities. PMID:25893015

  4. XPS and bioactivity study of the bisphosphonate pamidronate adsorbed onto plasma sprayed hydroxyapatite coatings

    NASA Astrophysics Data System (ADS)

    McLeod, Kate; Kumar, Sunil; Smart, Roger St. C.; Dutta, Naba; Voelcker, Nicolas H.; Anderson, Gail I.; Sekel, Ron

    2006-12-01

    This paper reports the use of X-ray photoelectron spectroscopy (XPS) to investigate bisphosphonate (BP) adsorption onto plasma sprayed hydroxyapatite (HA) coatings commonly used for orthopaedic implants. BPs exhibit high binding affinity for the calcium present in HA and hence can be adsorbed onto HA-coated implants to exploit their beneficial properties for improved bone growth at the implant interface. A rigorous XPS analysis of pamidronate, a commonly used nitrogenous BP, adsorbed onto plasma sprayed HA-coated cobalt-chromium substrates has been carried out, aimed at: (a) confirming the adsorption of this BP onto HA; (b) studying the BP diffusion profile in the HA coating by employing the technique of XPS depth profiling; (c) confirming the bioactivity of the adsorbed BP. XPS spectra of plasma sprayed HA-coated discs exposed to a 10 mM aqueous BP solution (pamidronate) for periods of 1, 2 and 24 h showed nitrogen and phosphorous photoelectron signals corresponding to the BP, confirming its adsorption onto the HA substrate. XPS depth profiling of the 2 h BP-exposed HA discs showed penetration of the BP into the HA matrix to depths of at least 260 nm. The bioactivity of the adsorbed BP was confirmed by the observed inhibition of osteoclast (bone resorbing) cell activity. In comparison to the HA sample, the HA sample with adsorbed BP exhibited a 25-fold decrease in primary osteoclast cells.

  5. Phase stability and biological property evaluation of plasma sprayed hydroxyapatite coatings for orthopedic and dental applications.

    PubMed

    Vahabzadeh, Sahar; Roy, Mangal; Bandyopadhyay, Amit; Bose, Susmita

    2015-04-01

    In this work we have investigated the effects of strontium (Sr) dopant on in vitro protein release kinetics and in vivo osteogenic properties of plasma sprayed hydroxyapatite (HA) coatings, along with their dissolution behavior. Plasma sprayed HA coatings are widely used in load-bearing implants. Apart from osseointegration, the new generation of HA coating is expected to deliver biomolecules and/or drugs that can induce osteoinduction. This paper reports the preparation of crystalline and amorphous HA coatings on commercially pure titanium (Cp-Ti) using inductively coupled radio frequency (RF) plasma spray, and their stability at different solution pH. Coatings prepared at 110 mm working distance from the nozzle showed an average Ca ion release of 18 and 90 ppm in neutral and acidic environments, respectively. Decreasing the working distance to 90 mm resulted in the formation of a coating with less crystalline HA and phases with higher solubility products, and consequently higher dissolution over 32 days. A 92% release of a model protein bovine serum albumin (BSA) in phosphate buffer with pH of 7.4 was measured for Sr-doped HA (Sr-HA) coating, while only a 72% release could be measured for pure HA coating. Distortion of BSA during adsorption on coatings revealed a strong interaction between the protein and the coating, with an increase in α-helix content. Osteoid formation was found on Sr-HA implants as early as 7 weeks post implantation compared to HA coated and uncoated Ti implants. After 12 weeks post implantation, osteoid new bone was formed on HA implants; whereas, bone mineralization started on Sr-HA samples. While no osteoid was formed on bare Ti surfaces, bone was completely mineralized on HA and Sr-HA coatings after 16 weeks post implantation. Our results show that both phase stability and chemistry can have a significant influence toward in vitro and in vivo response of HA coatings on Ti implants.

  6. Effect of substrate preheating temperature and coating thickness on residual stress in plasma sprayed hydroxyapatite coating

    NASA Astrophysics Data System (ADS)

    Tang, Dapei

    2015-07-01

    A thermal-mechanical coupling model was developed based on thermal-elastic- plastic theory according the special process of plasma spraying Hydroxyapatite (HA) coating upon Ti-6Al-4V substrate. On the one hand, the classical Fourier transient heat conduction equation was modified by introducing the effect item of deformation on temperature, on the other hand, the Johnson-Cook model, suitable for high temperature and high strain rate conditions, was used as constitutive equation after considering temperature softening effect, strain hardening effect and strain rate reinforcement effect. Based on the above coupling model, the residual stress field within the HA coating was simulated by using finite element method (FEM). Meanwhile, the substrate preheating temperature and coating thickness on the influence of residual stress components were calculated, respectively. The failure modes of coating were also preliminary analyzed. In addition, in order to verify the reliability of calculation, the material removal measurement technique was applied to determine the residual stress of HA coating near the interface. Some important conclusions are obtained.

  7. Induction plasma sprayed Sr and Mg doped nano hydroxyapatite coatings on Ti for bone implant.

    PubMed

    Roy, Mangal; Bandyopadhyay, Amit; Bose, Susmita

    2011-11-01

    In this study, we report fabrication of strontium (Sr) and magnesium (Mg) doped hydroxyapatite (HA) coating on commercially pure titanium (Cp-Ti) substrates using inductively coupled radio frequency (RF) plasma spray. HA powder was doped with 1 wt % Sr (Sr-HA) and 1 wt % Mg (Mg-HA), heat treated at 800°C for 6 h and then used for plasma spray coating. X-ray diffraction (XRD) and Fourier transformed infrared spectroscopic (FTIR) analysis indicated that the coatings were primarily composed of phase pure crystalline HA. When compared to undoped HA coating, physical properties such as microstructure, grain size, and adhesive bond strength of the doped HA coatings did not change significantly. Microstructure of the coatings showed coherency in the structure with an average grain size of 200-280 μm HA particles, where each of the HA grains consisted of 20-30 nm sized particles. An average adhesive bond strength of 17 MPa ensured sufficient mechanical strength of the coatings. A chemistry dependent improvement in bone cell-coating interaction was noticed for doped coatings although it had minimal effect on physical properties of the coatings. In vitro cell-materials interactions using human fetal osteoblasts (hFOB) showed better cell attachment and proliferation on Sr-HA coatings compared to HA or Mg-HA coatings. Presence of Sr in the coating also stimulated hFOB cell differentiation and alkaline phosphatase (ALP) expression. Improvement in bioactivity of Sr doped HA coatings on Ti without compromising its mechanical properties makes it an excellent material of choice for coated implant.

  8. Low-Energy Plasma Spray (LEPS) Deposition of Hydroxyapatite/Poly-ɛ-Caprolactone Biocomposite Coatings

    NASA Astrophysics Data System (ADS)

    Garcia-Alonso, Diana; Parco, Maria; Stokes, Joseph; Looney, Lisa

    2012-01-01

    Thermal spraying is widely employed to deposit hydroxyapatite (HA) and HA-based biocomposites on hip and dental implants. For thick HA coatings (>150 μm), problems are generally associated with the build-up of residual stresses and lack of control of coating crystallinity. HA/polymer composite coatings are especially interesting to improve the pure HA coatings' mechanical properties. For instance, the polymer may help in releasing the residual stresses in the thick HA coatings. In addition, the selection of a bioresorbable polymer may enhance the coatings' biological behavior. However, there are major challenges associated with spraying ceramic and polymeric materials together because of their very different thermal properties. In this study, pure HA and HA/poly-ɛ-caprolactone (PCL) thick coatings were deposited without significant thermal degradation by low-energy plasma spraying (LEPS). PCL has never been processed by thermal spraying, and its processing is a major achievement of this study. The influence of selected process parameters on microstructure, composition, and mechanical properties of HA and HA/PCL coatings was studied using statistical design of experiments (DOE). The HA deposition rate was significantly increased by the addition of PCL. The average porosity of biocomposite coatings was slightly increased, while retaining or even improving in some cases their fracture toughness and microhardness. Surface roughness of biocomposites was enhanced compared with HA pure coatings. Cell culture experiments showed that murine osteoblast-like cells attach and proliferate well on HA/PCL biocomposite deposits.

  9. Microstructural design of functionally graded coatings composed of suspension plasma sprayed hydroxyapatite and bioactive glass.

    PubMed

    Cattini, Andrea; Bellucci, Devis; Sola, Antonella; Pawłowski, Lech; Cannillo, Valeria

    2014-04-01

    Various bioactive glass/hydroxyapatite (HA) functional coatings were designed by the suspension plasma spraying (SPS) technique. Their microstructure, scratch resistance, and apatite-forming ability in a simulated body fluid (SBF) were compared. The functional coatings design included: (i) composite coating, that is, randomly distributed constituent phases; (ii) duplex coating with glass top layer onto HA layer; and (iii) graded coating with a gradual changing composition starting from pure HA at the interface with the metal substrate up to pure glass on the surface. The SPS was a suitable coating technique to produce all the coating designs. The SBF tests revealed that the presence of a pure glass layer on the working surface significantly improved the reactivity of the duplex and graded coatings, but the duplex coating suffered a relatively low scratch resistance because of residual stresses. The graded coating therefore provided the best compromise between mechanical reliability and apatite-forming ability in SBF. © 2013 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 102B: 551-560, 2014.

  10. Material fundamentals and clinical performance of plasma-sprayed hydroxyapatite coatings: a review.

    PubMed

    Sun, L; Berndt, C C; Gross, K A; Kucuk, A

    2001-01-01

    The clinical use of plasma-sprayed hydroxyapatite (HA) coatings on metal implants has aroused as many controversies as interests over the last decade. Although faster and stronger fixation and more bone growth have been revealed, the performance of HA-coated implants has been doubted. This article will initially address the fundamentals of the material selection, design, and processing of the HA coating and show how the coating microstructure and properties can be a good predictor of the expected behavior in the body. Further discussion will clarify the major concerns with the clinical use of HA coatings and introduce a comprehensive review concerning the outcomes experienced with respect to clinical practice over the past 5 years. A reflection on the results indicates that HA coatings can promote earlier and stronger fixation but exhibit a durability that can be related to the coating quality. Specific relationships between coating quality and clinical performance are being established as characterization methods disclose more information about the coating.

  11. Characterization of gas tunnel type plasma sprayed hydroxyapatite-nanostructure titania composite coatings

    NASA Astrophysics Data System (ADS)

    Yugeswaran, S.; Kobayashi, A.; Ucisik, A. Hikmet; Subramanian, B.

    2015-08-01

    Hydroxyapatite (HA) can be coated onto metal implants as a ceramic biocompatible coating to bridge the growth between implants and human tissue. Meanwhile many efforts have been made to improve the mechanical properties of the HA coatings without affecting its bioactivity. In the present study, nanostructure titania (TiO2) was mixed with HA powder and HA-nanostructure TiO2 composite coatings were produced by gas tunnel type plasma spraying torch under optimized spraying conditions. For this purpose, composition of 10 wt% TiO2 + 90 wt% HA, 20 wt% TiO2 + 80 wt% HA and 30 wt% TiO2 + 70 wt% HA were selected as the feedstock materials. The phase, microstructure and mechanical properties of the coatings were characterized. The obtained results validated that the increase in weight percentage of nanostructure TiO2 in HA coating significantly increased the microhardness, adhesive strength and wear resistance of the coatings. Analysis of the in vitro bioactivity and cytocompatibility of the coatings were done using conventional simulated body fluid (c-SBF) solution and cultured green fluorescent protein (GFP) labeled marrow stromal cells (MSCs) respectively. The bioactivity results revealed that the composite coating has bio-active surface with good cytocompatibility.

  12. Behavior of Plasma-Sprayed Hydroxyapatite Coatings onto Carbon/carbon Composites in Simulated Body Fluid

    NASA Astrophysics Data System (ADS)

    Sui, Jin-Ling; Bo, Wu; Hai, Zhou; Cao, Ning; Li, Mu-Sen

    Two types of hydroxyapatite (HA) coatings onto carbon/carbon composite (C/C composites) substrates, deposited by plasma spraying technique, were immersed in a simulated body fluid (SBF) in order to determine their behavior in conditions similar to the human blood plasma. Calcium ion concentration, pH value, microstructure, and phase compositions were analyzed. Results demonstrated that both the crystal Ca-P phases or the amorphous HA do dissolve slightly, and the dissolution of CaO phases in SBF was evident after 1 day of soaking. The calcium-ion concentration was decreased and the pH value of SBF was increased with the increasing of the immersing time. The precipitation was mainly composed of HA, which was verified by X-ray diffraction (XRD) and electron-probe microanalyzer.

  13. Acoustic emission and fatigue damage induced in plasma-sprayed hydroxyapatite coating layers.

    PubMed

    Laonapakul, Teerawat; Otsuka, Yuichi; Nimkerdphol, Achariya Rakngarm; Mutoh, Yoshiharu

    2012-04-01

    In order to improve the adhesive strength of hydroxyapatite (HAp) coatings, grit blasting with Al(2)O(3) powder and then wet blasting with HAp/Ti mixed powders was carried out on a commercially pure Ti (cp-Ti) substrate. Subsequently, an HAp/Ti bond coat layer and HAp top coat layer were deposited by plasma spraying. Fatigue tests of the HAp-coated specimens were carried out under four-point bending. Acoustic emission (AE) signals during the entire fatigue test were monitored to investigate the fatigue cracking behavior of the HAp-coated specimens. The HAp-coated specimens could survive up to 10(7) cycles without spallation of the HAp coating layers at the stress amplitude of 120 MPa. The HAp-coated specimens without HAp/Ti bond coat layer showed shorter fatigue life and easy crack nucleation compared to the HAp-coated specimens with HAp/Ti bond coat layer. The delamination and spallation of the HAp top coat with HAp/Ti bond coat on cp-Ti was not observed until the crack propagated into the cp-Ti during the final fracture stage of the fatigue cycle. Therefore, the HAp/Ti bond coat layer was found to greatly improve the fatigue damage resistance of the HAp coating layer. Three stages of the fatigue failure behavior of the HAp top coat with HAp/Ti bond coat on a cp-Ti substrate can be clearly estimated by the AE monitoring technique. These stages are cracks nucleating and propagating in the coating layer, cracks propagating in the substrate, and cracks propagating unstably to final fracture.

  14. Adhesive and cohesive properties by indentation method of plasma-sprayed hydroxyapatite coatings

    NASA Astrophysics Data System (ADS)

    Mohammadi, Z.; Ziaei-Moayyed, A. A.; Mesgar, A. Sheikh-Mehdi

    2007-03-01

    Adhesive and cohesive properties of the plasma-sprayed hydroxyapatite (HA) coatings, deposited on Ti-6Al-4V substrates by varying the plasma power level and spray distance (SD), were evaluated by an indentation method. The crystallinity and the porosity decreased with increasing both of these two parameters. The microhardness value, Young's modulus ( E) and coating fracture toughness ( KC) were found to increase with a combinational increase in spray power and SD. The Knoop and Vickers indentation methods were used to estimate E and KC, respectively. The critical point at which no crack appears at the interface was determined by the interface indentation test. This was used to define the apparent interfacial toughness ( KCa) which is representative of the crack initiation resistance of the interface. It was found that KCa reaches to a maximum at a medium increase in both spray power and SD, while other mechanical properties of the coatings reaches to the highest value with further increase in these two plasma parameters. The tensile adhesion strength of the coatings, measure by the standard adhesion test, ISO 13779-4, was shown to alter in the same manner with KCa results. It was deduced that a combinational increase in spray power and SD which leads to a higher mechanical properties in the coatings, does not necessarily tends to a better mechanical properties at the interface.

  15. Plasma-sprayed coatings

    SciTech Connect

    Herman, H.

    1988-09-01

    Plasma spraying is one way to apply protective coatings. The hot, high-speed flame of a plasma gun can melt a powder of almost any ceramic or metal and spray it to form a coating for protection against corrosion, wear or high temperature. The technique carries much less risk of degrading the coating and substrate than many other high-temperature processes do, because the gas in the plasma flame is chemically inert and the target can be kept fairly cool. And yet a plasma gun can be only a little more cumbersome than a paint sprayer. Investigators are applying this technique to new materials. The General Electric Company is using vacuum plasma spraying to make freestanding components: intricate aircraft engine parts formed by plasma-spraying a superalloy on a removable substrate. Other workers spray ceramic particles or fibers and metal powder simulatious wrong, stiff composite materials: the ceramic particles dispersed in a matrix of metal. The author and colleagues at the U.S. Naval Research Laboratory have fabricated a thick film of high-temperature superconductor by plasma-spraying the compound in the form of a powder. 7 figs.

  16. Nanocrystalline structure of the surface layer of plasma-sprayed hydroxyapatite coatings obtained upon preliminary induction heat treatment of metal base

    NASA Astrophysics Data System (ADS)

    Fomin, A. A.; Steinhauer, A. B.; Lyasnikov, V. N.; Wenig, S. B.; Zakharevich, A. M.

    2012-05-01

    Biocompatible nanocrystalline hydroxyapatite (HA) coatings for intrabone titanium implants have been obtained by plasma spraying. The HA coatings have an average grain size within 10-30 nm and are characterized by improved characteristics of morphological heterogeneity that is acquired due to the induction heat treatment (IHT) of substrates prior to plasma spray deposition. Based on the data of scanning electron microscopy with computer-aided processing of images, it is established that the average grain size depends on the IHT temperature.

  17. Plasma-sprayed hydroxyapatite coating on carbon/carbon composite scaffolds for bone tissue engineering and related tests in vivo.

    PubMed

    Cao, Ning; Dong, Jianwen; Wang, Qiangxiu; Ma, Quansheng; Wang, Feng; Chen, Huaying; Xue, Chengqian; Li, Musen

    2010-03-01

    The bioactive hydroxyapatite (HA) coatings were successfully prepared on carbon/carbon composites (C/C) by means of sand-blasting pretreatment and plasma-spraying technology. X-ray diffraction was employed to analyze the phase constitute of the coatings. Meanwhile, the bond strength between the HA coatings and C/C substrates was determined via shear test. Experimental results show that the coatings constitute HA, CaO, and other amorphous phosphates. The post heat treatment could effectively increase crystallization and purity of the coatings. Through observation and analysis by electron microprobe and scanning electron microscopy, it is concluded that the bond strength of the plasma-sprayed HA coatings on C/C is mainly determined by the interface structure and can be further improved by the post heat treatment. Meanwhile, the implantation in vivo was carried out in hybrid goats. The histological observation revealed that the osteoplaque gradually grew on the surface of the HA coatings and the pure C/C surface was covered by the fibrous tissues. No inflammation symptoms were found in the bone tissue around the implants.

  18. Induction of osteoconductivity by BMP-2 gene modification of mesenchymal stem cells combined with plasma-sprayed hydroxyapatite coating

    NASA Astrophysics Data System (ADS)

    Wu, Jiang; Guo, Ying-qiang; Yin, Guang-fu; Chen, Huai-qing; Kang, Yunqing

    2008-11-01

    Success in bone implant depends greatly on the composition and surface features of the implant. The surface-modification measures not only favor the implant's osteoconductivity, but also promote both bone anchoring and biomechanical stability. This paper reports an approach to combine a hydroxyapatite (HA) coated substrate with a cellular vehicle for the delivery of bone morphogenetic protein-2 (BMP-2) synergistically enhancing the osteoconductivity of implant surfaces. We examined the attachment, growth and osteoinductive activity of transfected BMP-producing bone marrow mesenchymal stem cells (BMSCs) on a plasma-sprayed HA coated substrate. It was found that the HA coated substrate could allow the attachment and growth of BMP-2 gene modified BMSCs, and this combined application synergistically enhanced osteconductivity of the substrate surface. This synergistic method may be of osseointegration value in orthopedic and dental implant surgery.

  19. In vitro biological response of plasma electrolytically oxidized and plasma-sprayed hydroxyapatite coatings on Ti-6Al-4V alloy.

    PubMed

    Yeung, Wing Kiu; Reilly, Gwendolen C; Matthews, Allan; Yerokhin, Aleksey

    2013-08-01

    Plasma electrolytic oxidation (PEO) is a relatively new surface modification process that may be used as an alternative to plasma spraying methods to confer bioactivity to Ti alloy implants. The aim of this study was to compare physical, chemical and biological surface characteristics of two coatings applied by PEO processes, containing different calcium phosphate (CaP) and titanium dioxide phases, with a plasma-sprayed hydroxyapatite (HA) coating. Coating characteristics were examined by X-ray diffraction, energy dispersive X-ray spectroscopy, scanning electron microscopy, surface profilometry, and wettability tests. The biological properties were determined using the human osteoblastic cell line MG-63 to assess cell viability, calcium and collagen synthesis. The tests showed that PEO coatings are significantly more hydrophilic (6%) and have 78% lower surface roughness (Ra) than the plasma-sprayed coatings. Cell behavior was demonstrated to be strongly dependent on the phase composition and surface distribution of elements in the PEO coating. MG-63 viability for the TiO2 -based PEO coating containing amorphous CaPs was significantly lower than that for the PEO coating containing crystalline HA and the plasma-sprayed coating. However, collagen synthesis on both the CaP and the TiO2 PEO coatings was significantly higher (92% and 71%, respectively) than on the plasma-sprayed coating after 14 days. PEO has been demonstrated to be a promising method for coating of orthopedic implant surfaces.

  20. SEM analysis of plasma-sprayed hydroxyapatite coatings obtained with induction preheating of titanium substrate

    NASA Astrophysics Data System (ADS)

    Fomina, Marina A.; Fomin, Aleksandr A.

    2015-03-01

    Production of biocompatible nano-ceramic coatings is one of the major goals in prospective materials technology, particularly, in biomedical items, e.g. intraosseous implants and joint endoprostheses. Ceramic coatings obtained by the existing methods do not have the required structural properties of biocompatibility, which causes quality reduction. It has been stated that thermal induction preheating of substrate ensures the required structural organization of hydroxyapatite coating, grain size and shape in particular.

  1. Electrochemical behavior of different preparations of plasma-sprayed hydroxyapatite coatings on Ti6Al4V substrate.

    PubMed

    Souto, Ricardo M; Lemus, M Mercedes; Reis, Rui L

    2004-07-01

    The corrosion behavior of four different preparations of plasma-sprayed hydroxyapatite (HA) coatings on Ti6Al4V substrates in static Hank's balanced salt solution was investigated using dc potentiodynamic and ac impedance techniques. Two different nominal thicknesses, 50 microm and 200 microm, and two different spraying conditions, were considered. The electrochemical impedance experiments proved this technique to be very suitable for the investigation of the electrochemical behavior of surgical implant alloys when they are coated with HA, which is characterized by the dissolution and passivation characteristics of the underlying metal substrate. Because the coatings are porous, ionic paths between the electrolytic medium and the base material can eventually be produced, resulting in the corrosion of the coated metal. Differences in the corrosion resistance of the coated materials were detected, and a relevant model for the description of the coating degradation in the biosimulating solution was proposed. The model consisted of the description of the coated system in terms of a two-layer model of the surface film. Significant differences in electrochemical behavior for similar nominal thicknesses of HA coatings obtained under different spraying conditions were found.

  2. Effect of Spray Distance on Microstructure and Tribological Performance of Suspension Plasma-Sprayed Hydroxyapatite-Titania Composite Coatings

    NASA Astrophysics Data System (ADS)

    Zhang, Chao; Xu, Haifeng; Geng, Xin; Wang, Jingjing; Xiao, Jinkun; Zhu, Peizhi

    2016-10-01

    Hydroxyapatite (HA)-titania (TiO2) composite coatings prepared on Ti6Al4V alloy surface can combine the excellent mechanical property of the alloy substrate and the good biocompatibility of the coating material. In this paper, HA-TiO2 composite coatings were deposited on Ti6Al4V substrates using suspension plasma spray (SPS). X-ray diffraction, scanning electron microscopy, Fourier infrared absorption spectrometry and friction tests were used to analyze the microstructure and tribological properties of the obtained coatings. The results showed that the spray distance had an important influence on coating microstructure and tribological performance. The amount of decomposition phases decreased as the spray distance increased. The increase in spray distance from 80 to 110 mm improved the crystalline HA content and decreased the wear performance of the SPS coatings. In addition, the spray distance had a big effect on the coating morphology due to different substrate temperature resulting from different spray distance. Furthermore, a significant presence of OH- and CO3 2- was observed, which was favorable for the biomedical applications.

  3. Significance of in-situ dry-ice blasting on the microstructure, crystallinity and bonding strength of plasma-sprayed hydroxyapatite coatings.

    PubMed

    Dong, Shujuan; Zeng, Jinyan; Li, Lifen; Sun, Junbin; Yang, Xiong; Liao, Hanlin

    2017-03-07

    To obtain hydroxyapatite (HA) coatings with high crystallinity which have long-term stability in clinical applications, coarse powders were usually injected to less energetic plasma. However, the HA coatings accumulated by partly melted particles usually have high porosity and poor mechanical properties, especially poor bonding strength. In this work, by profiting its quenching and mechanical impact, dry-ice blasting was in-situ employed during plasma spray process to improve the microstructure characterization and bonding strength of HA coatings. In addition, the influence of in-situ dry-ice blasting on the phase composition and crystallinity of plasma-sprayed HA coatings was investigated. The results show that a significant reduction of porosity and an apparent increase in bonding strength are revealed in plasma-sprayed HA coatings due to the cleaning effect of dry-ice blasting on the convex unmelted particles and splashing fragments. HA coatings prepared by the combination process of plasma spraying and dry-ice blasting have a compromise structure with minimum globular pores but with pronounced microcracks. The disappearance of CaO phase and the increase in crystallinity also derive from the application of dry-ice blasting.

  4. Plasma sprayed hydroxyapatite coatings on titanium substrates. Part 1: Mechanical properties and residual stress levels.

    PubMed

    Tsui, Y C; Doyle, C; Clyne, T W

    1998-11-01

    Hydroxyapatite (HA) coatings have been sprayed on to substrates of Ti-6Al-4V, using a range of input power levels and plasma gas mixtures. Coatings have also been produced on substrates of mild steel and tungsten, in order to explore certain aspects of the mechanical behaviour of HA without the complication of yielding or creep in the substrate. Studies have been made of the phase constitution, porosity, degree of crystallinity, OH ion content, microstructure and surface roughness of the HA coatings. The Young's moduli in tension and in compression were evaluated by the cantilever beam bend test using a tungsten/HA composite beam. The flexural Young's modulus was determined using a free-standing deposit under the same test. Adhesion was characterised using the single-edge notch-bend test; this is considered superior to the tensile bond strength test in common use. Measured interfacial fracture energies were of the order 1-10 J m(-2). Stress levels were investigated using specimen curvature measurements in conjunction with a numerical process model. The quenching stress for HA was measured to be about 10-25 MPa and the residual stress level in HA coatings at room temperature are predicted to lie in the approximate range of 20-40 MPa (tensile). These residual stresses could be reduced in magnitude by maintaining the substrate at a low temperature (possibly below room temperature) during spraying and it may be worthwhile to explore this. Ideally, the HA coating should have low porosity, high cohesive strength, good adhesion to the substrate, a high degree of crystallinity and high chemical purity and phase stability. In practice, such combinations are rather difficult to achieve by just varying the spraying parameters.

  5. Spheroidized Hydroxyapatite (HA) Powders Plasma Spraying of Combustion Flame

    NASA Astrophysics Data System (ADS)

    Khor, K. A.; Wang, Y.; Cheang, P.

    1998-06-01

    Tailoring powder characteristics to suit the plasma spray process can alleviate difficulties associated with the preparation of hydroxyapatite (HA) coatings. Commercial HA feedstock normally exhibit an angular morphology and a wide particle size range that present difficulties in powder transport from the powder hopper to the plasma spray gun and in nonuniform melting of the powders in the plasma flame. Hence, combustion flame spheroidized hydroxyapatite (SHA) was used as the feedstock for plasma spraying. Spherical particles within a narrow particle size range are found to be more effective for the plasma spray processes. Results show coatings generated from spheroidized HA powders have unique surface and microstructure characteristics. Scanning electron microscope (SEM) observation of the coating surface revealed well-formed splats that spread and flatten into disc configurations with no disintegration, reflecting adequate melting of the HA in the plasma and subsequent deposition consistency. The surface topography is generally flat with good overlapping of subsequent spreading droplets. Porosity in the form of macropores is substantially reduced. The cross-section microstructure reveals a dense coating comprised of randomly stacked lamellae. The tensile bond strengths of the SHA coatings, phase composition, and characteristics of the coatings generated with different particle sizes (125 to 75 µm, 45 to 75 µm, 20 to 45 µm, and 5 to 20 µm) showed that a high bond strength of ˜16 MPa can be obtained with SHA in the size range from 20 to 45 µm. This can be improved further by a postspray treatment by hot isostatic pressing (HIP). However, larger particle size ranges exhibited higher degrees of crystallinity and relatively higher HA content among the various calcium phosphate phases found in the coatings.

  6. Vacuum Plasma Sprayed Metallic Coatings

    NASA Astrophysics Data System (ADS)

    Shankar, S.; Koenig, D. E.; Dardi, L. E.

    1981-10-01

    Recognizing the fundamental cost advantage, technical capabilities, and compositional flexibility of reduced pressure (vacuum) plasma spraying compared to other overlay coating methods, an advanced, second generation, closed chamber deposition process called VPX (a Howmet trademark) was developed. An automated experimental facility for coating gas turbine engine components was also constructed. This paper describes several important features of the process and equipment. It shows that the use of optimized spray parameters combined with an appropriate schedule of relative orientations between the gun and work-piece can be used to produce dense and highly reproducible coatings of either uniform or controlled thickness distributions. The chemical composition, microstructure, and interfacial characteristics of typical MCrAlY coatings are reported. Some effects of operating procedures and MCrAlY chemical composition on coating density are noted. The results of mechanical property and burner rig tests of coated material are also described.

  7. Thermal residual stresses near the interface between plasma-sprayed hydroxyapatite coating and titanium substrate: finite element analysis and synchrotron radiation measurements.

    PubMed

    Cofino, B; Fogarassy, P; Millet, P; Lodini, A

    2004-07-01

    Plasma-sprayed hydroxyapatite (HA) coatings on titanium alloy are often used in prosthetic implants. The metallic substrate gives the implant good mechanical strength which is combined with good biocompatibility and osteointegration of the ceramic coating. However, the interface between the HA coating and titanium alloy substrate is an area of critical weakness when compared with the interlamellar cohesive strength of the HA coating structure. Knowledge of the stresses in materials near the interface seems to be an important step in understanding why failure occurs. Synchrotron radiation, using Beamline BM16 at the European Synchrotron Radiation Facility (Grenoble, France), has been used to determine local stresses near the interface, down to 10 microm in resolution, between a plasma-sprayed HA coating and a titanium alloy substrate. This experimental determination of residual stresses is compared with the results found by a finite element analysis modeling the thermal effects of the plasma-spraying process. Residual stresses have been found in deposited ceramic near the interface due to a thermal properties mismatch of the materials. If the plane stress state is assumed, meaning the perpendicular component of residual stress is ignored (sigma(z) = 0), then the synchrotron residual stress measurements should be interpreted as mainly compressive in the ceramic coating. This is in contradiction with the coefficient of thermal expansion mismatch; therefore, the simplified plane stresses assumption seems to be inappropriate for the deposited morphology characterized by pores and a network of microcracks. The detailed finite element analysis model, taking into account the real morphology of the coating and the real three-dimensional stress field distribution, allowed the estimation of sigma(z), leading to a more accurate interpretation of synchrotron measurements, which is validated by the experimental results.

  8. Evaluation of titanium plasma-sprayed and plasma-sprayed hydroxyapatite implants in vivo.

    PubMed

    Ong, Joo L; Carnes, David L; Bessho, Kazuhisa

    2004-08-01

    In this study, bone interfacial strength and bone contact length at the plasma-sprayed hydroxyapatite (HA) and titanium plasma-sprayed (TPS) implants were evaluated in vivo. Non-coated titanium (Ti) implants were used as controls. Cylindrical coated or non-coated implants (4.0mm diameter by 8mm long) were implanted in the dogs' mandibles. Loading of the implants was performed at 12 weeks after implantation. At 12 weeks after implantation (prior to loading) and 1 year after loading, implants were evaluated for interfacial bone-implant strength and bone-implant contact length. No significant differences in interfacial bone-implant strength for all groups at 12 weeks after implantation and after 1 year loading in normal bone were found. However, bone contact length for HA implants was significantly higher than the TPS and Ti implants for both periods tested (12 weeks after implantation and 1 year after loading). It was concluded that TPS implants exhibited similar pull-out strength compared to the HA implants. In addition, the lower bone contact length on the TPS surface compared to HA surfaces did not affect the interfacial bone-implant strength for both implants.

  9. Microstructural Healing with Interfacial Reaction Layers on the Adhesive Strength Enhancement of Plasma-Sprayed Hydroxyapatite Coatings

    NASA Astrophysics Data System (ADS)

    Yang, Chung-Wei; Lui, Truan-Sheng

    The effect of hydrothermal crystallization and adding reinforced intermediate layers on improving the tensile adhesion of plasma-sprayed HA coatings (HAC) was investigated. The experimental results show that the index of crystallinity (IOC) and phase purity of hydrothermally-treated HAC (HT-HAC) are increased by the low-temperature hydrothermal treatment. The microstructural healing effect with nano-size HA crystallites is significant to diminish the defects and prevent mechanical strength degradation for the HT-HAC. XPS analysis demonstrates that hydrothermal crystallization helps to promote the interfacial Ti-OH chemical reaction. HA composite coatings with CP-Ti and ZrO2 intermediate layers provide another strengthening effect compared with the hydrothermal-heating method. The inter-diffusion of Ca results in a chemical bonding at the HA/ZrO2 interface, which results in the increase of the adhesive strength of composite coatings. The fracture behavior is different between the crystallization-induced HAC and the composite coatings. The HT-HAC remains on the substrate with an evident cohesive failure. The adhesive failure occurred at HA/intermediate layers for composite coatings. Failures with less percentage area of interfacial fracture are indicative of a higher strength of a coating.

  10. Cyclic delamination behavior of plasma-sprayed hydroxyapatite coating on Ti-6Al-4V substrates in simulated body fluid.

    PubMed

    Otsuka, Yuichi; Kawaguchi, Hayato; Mutoh, Yoshiharu

    2016-10-01

    This study aimed to clarify the effect of a simulated body fluid (SBF) on the cyclic delamination behavior of a plasma-sprayed hydroxapatite (HAp) coating. A HAp coating is deposited on the surfaces of surgical metallic materials in order to enhance the bond between human bone and such surfaces. However, the HAp coating is susceptible to delamination by cyclic loading from the patient's gait. Although hip joints are subjected to both positive and negative moments, only the effects of tensile bending stresses on vertical crack propagation behavior have been investigated. Thus, the cyclic delamination behavior of a HAp coating was observed at the stress ratio R=-1 in order to determine the effects of tensile/compressive loading on the delamination behavior. The delamination growth rate increased with SBF immersion, which decreased the delamination life. Raman spectroscopy analysis revealed that the selective phase dissolution in the HAp coating was promoted at interfaces. Finite element analysis revealed that the energy release rate Gmax showed a positive value even in cases with compressive loading, which is a driving force for the delamination of a HAp coating. A prediction model for the delamination growth life was developed that combines a fracture mechanics parameter with the assumed stress-dependent dissolution rate. The predicted delamination life matched the experimental data well in cases of lower stress amplitudes with SBF.

  11. Plasma-Sprayed Photocatalytic Zinc Oxide Coatings

    NASA Astrophysics Data System (ADS)

    Navidpour, A. H.; Kalantari, Y.; Salehi, M.; Salimijazi, H. R.; Amirnasr, M.; Rismanchian, M.; Azarpour Siahkali, M.

    2017-03-01

    Fabrication of semiconductor coatings with photocatalytic action for photodegradation of organic pollutants is highly desirable. In this research, pure zinc oxide, which is well known for its promising photocatalytic activity, was deposited on stainless-steel plates by plasma spraying. The phase composition and microstructure of the deposited films were studied by x-ray diffraction analysis and scanning electron microscopy, respectively. Despite the low-energy conditions of the plasma spraying process, the zinc oxide coatings showed good mechanical integrity on the substrate. Their photocatalytic activity was evaluated using aqueous solution of methylene blue at concentration of 5 mg L-1. The results showed the potential of the plasma spraying technique to deposit zinc oxide coatings with photocatalytic action under ultraviolet illumination. Ultraviolet-visible (UV-Vis) diffuse reflectance spectroscopy confirmed that the plasma spraying method could deposit zinc oxide films with higher photoabsorption ability relative to the initial powder.

  12. Plasma-Spray Metal Coating On Foam

    NASA Technical Reports Server (NTRS)

    Cranston, J.

    1994-01-01

    Molds, forms, and other substrates made of foams coated with metals by plasma spraying. Foam might be ceramic, carbon, metallic, organic, or inorganic. After coat applied by plasma spraying, foam left intact or removed by acid leaching, conventional machining, water-jet cutting, or another suitable technique. Cores or vessels made of various foam materials plasma-coated with metals according to method useful as thermally insulating containers for foods, liquids, or gases, or as mandrels for making composite-material (matrix/fiber) parts, or making thermally insulating firewalls in automobiles.

  13. Deposition of Hard Chrome Coating onto Heat Susceptible Substrates by Low Power Microwave Plasma Spray

    NASA Astrophysics Data System (ADS)

    Redza, Ahmad; Yasui, Toshiaki; Fukumoto, Masahiro

    2016-02-01

    Microwave plasma spray requires relatively low power, which is lower than 1 kW in comparison to other plasma spraying method. Until now, we are able to deposit Cu and Hydroxyapatite coating onto heat susceptible substrate, CFRP which are difficult for conventional plasma spray due to the excessive heat input. In this paper, a hard chromium coating was deposited onto SUS304 and CFRP by a low power microwave plasma spray technique. By controlling the working gas flow rate and spraying distance, a hard chrome coating with thickness of approximately 30 μm was successfully deposited onto CFRP substrate with hardness of 1110 Hv0.05. Furthermore, the coating produced here is higher than that produced by hard chrome plating.

  14. Hydroxyapatite in total hip arthroplasty. Our experience with a plasma spray porous titanium alloy/hydroxyapatite double-coated cementless stem

    PubMed Central

    Castellini, Iacopo; Andreani, Lorenzo; Parchi, Paolo Domenico; Bonicoli, Enrico; Piolanti, Nicola; Risoli, Francesca; Lisanti, Michele

    2016-01-01

    Summary Purpose Total hip arthroplasty could fail due to many factors and one of the most common is the aseptic loosening. In order to achieve an effective osseointegration and reduce risk of lossening, the use of cemented implant, contact porous bearing surface and organic coating were developed. Aim of this study was to evaluate clinical and radiological mid-term outcomes of a porous titanium alloy/hydroxyapatite double coating manufactured cementless femoral stem applied with “plasma spray” technique and to demonstrate the possibility to use this stem in different types of femoral canals. Methods Between January 2008 and December 2012, 240 consecutive primary total hip arthroplasties (THAs) were performed using a porous titanium alloy/hydroxyapatite double coating manufactured cementless femoral stem. 182 patients were examined: 136 were females (74.7%) and 46 males (25.2%); average age was 72 years old (ranging from 26 to 92 years old). For each patient, Harris Hip Scores (HHS) and Womac Scores were collected. All X-ray images were analyzed in order to demonstrate stem survival rate and subsidence. Results Harris Hip Score was good or excellent in 85% of the cases (average 90%) and mean WOMAC score was 97.5 (ranging from 73.4 to 100). No cases of early/late infection or periprosthetic fracture were noticed, with an excellent implant survival rate (100%) in a mean period of 40 months (ranging from 24 and 84 months). 5 cases presented acute implant dislocation, 2 due to wrong cup positioning in a dysplastic acetabulum and 3 after ground level fall. Dorr classification of femoral geometry was uses and the results were: 51 type A bone, 53 type B bone and 78 type C bone. Stem subsidence over 2 mm was considered as a risk factor of future implant loosening and was evidenced in 3 female patients with type C of Dorr classification. No radiolucencies signs around the proximally coated portion of stem or proximal reabsorption were visible during the radiographic

  15. Thermal Expansion of Vacuum Plasma Sprayed Coatings

    NASA Technical Reports Server (NTRS)

    Raj, S V.; Palczer, A. R.

    2010-01-01

    Metallic Cu-8%Cr, Cu-26%Cr, Cu-8%Cr-1%Al, NiAl and NiCrAlY monolithic coatings were fabricated by vacuum plasma spray deposition processes for thermal expansion property measurements between 293 and 1223 K. The corrected thermal expansion, (DL/L(sub 0) varies with the absolute temperature, T, as (DL/L(sub 0) = A(T - 293)(sup 3) + BIT - 293)(sup 2) + C(T - 293) + D, where, A, B, C and D are thermal, regression constants. Excellent reproducibility was observed for all of the coatings except for data obtained on the Cu-8%Cr and Cu-26%Cr coatings in the first heat-up cycle, which deviated from those determined in the subsequent cycles. This deviation is attributed to the presence of residual stresses developed during the spraying of the coatings, which are relieved after the first heat-up cycle. In the cases of Cu-8%Cr and NiAl, the thermal expansion data were observed to be reproducible for three specimens. The linear expansion data for Cu-8% Cr and Cu-26%Cr agree extremely well with rule of mixture (ROM) predictions. Comparison of the data for the Cu-8%Cr coating with literature data for Cr and Cu revealed that the thermal expansion behavior of this alloy is determined by the Cu-rich matrix. The data for NiAl and NiCrAlY are in excellent agreement with published results irrespective of composition and the methods used for processing the materials. The implications of these results on coating GRCop-84 copper alloy combustor liners for reusable launch vehicles are discussed.

  16. Plasma sprayed and electrospark deposited zirconium metal diffusion barrier coatings

    SciTech Connect

    Hollis, Kendall J; Pena, Maria I

    2010-01-01

    Zirconium metal coatings applied by plasma spraying and electrospark deposition (ESD) have been investigated for use as diffusion barrier coatings on low enrichment uranium fuel for research nuclear reactors. The coatings have been applied to both stainless steel as a surrogate and to simulated nuclear fuel uranium-molybdenum alloy substrates. Deposition parameter development accompanied by coating characterization has been performed. The structure of the plasma sprayed coating was shown to vary with transferred arc current during deposition. The structure of ESD coatings was shown to vary with the capacitance of the deposition equipment.

  17. Phase analysis of plasma-sprayed zirconia-yttria coatings

    NASA Technical Reports Server (NTRS)

    Shankar, N. R.; Berndt, C. C.; Herman, H.

    1983-01-01

    Phase analysis of plasma-sprayed 8 wt pct-yttria-stabilized zirconia (YSZ) thermal barrier coatings and powders was carried out by X-ray diffraction. Step scanning was used for increased peak resolution. Plasma spraying of the YSZ powder into water or onto a steel substrate to form a coating reduced the cubic and monoclinic phases with a simultaneous increase in the tetragonal phase. Heat treatment of the coating at 1150 C for 10 h in an Ar atmosphere increased the amount of cubic and monoclinic phases. The implications of these transformations on coating performance and integrity are discussed.

  18. Influence of plasma spraying deposition process on optical properties of hydroxyapatite

    NASA Astrophysics Data System (ADS)

    Belka, Radosław; Kowalski, Szymon; Żórawski, Wojciech; Suchańska, Małgorzata

    2015-09-01

    Hydroxyapatite (HAp) is a well-known bioceramic, nonorganic material of the bones of the vertebrate responsible for their mechanical durability. In human bones it occupies 60-80 % of the volume depending on a number of factors. Synthetic HAp is valued in bone endoprosthetic to its high biocompatibility. It is widely used to fill cavities of bone and as the coating of bone implants to increase their biocompatibility and adhesion to bone surface. In this paper a diffuse reflectance spectra of plasma-spraying deposited hydroxyapatite were presented and compared with pure powder samples. Optical band gap were estimated basing on Kubelka-Munk functions and Tauc plot extrapolation. We found that deposition process affects the value of band gap.

  19. Thermophysical properties of plasma sprayed coatings

    NASA Technical Reports Server (NTRS)

    Wilkes, K. E.; Lagedrost, J. F.

    1973-01-01

    Thermophysical properties of plasma sprayed materials were determined for the following plasma sprayed materials: CaO - stabilized ZrO2, Y2O3 - stabilized ZerO2, Al2O3, HfO2 Mo, nichrome, NiAl, Mo-ZrO2, and MoAl2O3 mixtures. In all cases the thermal conductivity of the as-sprayed materials was found to be considerably lower than that of the bulk material. The flash-laser thermal diffusivity technique was used both for diffusivity determination of single-layer materials and to determine the thermal contact resistance at the interface of two-layer specimens.

  20. Structure and Properties of Modified Plasma-Sprayed Composite Coatings on a Titanium Base

    NASA Astrophysics Data System (ADS)

    Mal'tseva, S. V.; Mel'nikova, I. P.; Lyasnikova, A. V.; Zaharevich, A. M.

    2016-09-01

    The structure and properties of hydroxyapatite (HA) plasma-sprayed coatings modified by Al2O3 and AlOOH nanoparticles have been investigated using different methods. It is found that the impregnation of HA particles before forming the coating ensures their most uniform distribution in the coating and increases its adhesion to 17.6 MPa. Agglomeration and milling of the powder mixture before spraying contribute to the formation of a uniform porous structure of the coating and a developed surface morphology with an increased adhesion from 10.4 to 17.8 MPa.

  1. Corrosion behavior of magnetic ferrite coating prepared by plasma spraying

    SciTech Connect

    Liu, Yi; Wei, Shicheng Tong, Hui; Tian, Haoliang; Liu, Ming; Xu, Binshi

    2014-12-15

    Graphical abstract: The saturation magnetization (M{sub s}) of the ferrite coating is 34.417 emu/g while the M{sub s} value of the ferrite powder is 71.916 emu/g. It can be seen that plasma spray process causes deterioration of the room temperature soft magnetic properties. - Highlights: • Spinel ferrite coatings have been prepared by plasma spraying. • The coating consists of nanocrystalline grains. • The saturation magnetization of the ferrite coating is 34.417 emu/g. • Corrosion behavior of the ferrite coating was examined in NaCl solution. - Abstract: In this study, spray dried spinel ferrite powders were deposited on the surface of mild steel substrate through plasma spraying. The structure and morphological studies on the ferrite coatings were carried out using X-ray diffraction, scanning electron microscope and Raman spectroscopy. It was showed that spray dried process was an effective method to prepare thermal spraying powders. The coating showed spinel structure with a second phase of LaFeO{sub 3}. The magnetic property of the ferrite samples were measured by vibrating sample magnetometer. The saturation magnetization (M{sub s}) of the ferrite coating was 34.417 emu/g. The corrosion behavior of coating samples was examined by electrochemical impedance spectroscopy. EIS diagrams showed three corrosion processes as the coating immersed in 3.5 wt.% NaCl solution. The results suggested that plasma spraying was a promising technology for the production of magnetic ferrite coatings.

  2. The effect of plasma-sprayed coatings on the fatigue of titanium alloy implants

    NASA Astrophysics Data System (ADS)

    Smith, Todd

    1994-02-01

    The application of titanium plasma-spray coatings to Ti-6Al-4V orthopedic implants results in a dramatic decrease in high-cycle fatigue performance. The better bonding of the plasma sprayed and heat-treated implants results in a lower high-cycle fatigue strength. Therefore, the use of plasma-spray textured coatings on implants must be considered with caution.

  3. A plasma-sprayed valve coating

    NASA Technical Reports Server (NTRS)

    Brennan, A.; Olmore, A. B.

    1980-01-01

    Need to reduce wear on nickel alloy seats and poppets for Space Shuttle main engine led to fused cobalt/tungsten carbide coating. Coating, which is dense, wear-resistant, and nonporous, can be applied in controlled amounts to various substrate configurations. Ease of application to parts with intricate shapes and contours should make coating useful in automotive and aircraft manufacturing.

  4. Plasma-sprayed self-lubricating coatings

    NASA Technical Reports Server (NTRS)

    Nakamura, H. H.; Logan, W. R.; Harada, Y.

    1982-01-01

    One of the most important criterion for acceptable commercial application of a multiple phase composition is uniformity and reproducibility. This means that the performance characteristics of the coat - e.g., its lubricating properties, bond strength to the substrate, and thermal properties - can be readily predicted to give a desired performance. The improvement of uniformity and reproducibility of the coats, the oxidation behavior at three temperature ranges, the effect of bond coat and the effect of preheat treatment as measured by adhesive strength tests, coating examination procedures, and physical property measurements were studied. The following modifications improved the uniformity and reproducibility: (1) changes and closer control in the particle size range of the raw materials used, (2) increasing the binder content from 3.2% to 4.1% (dried weight), and (3) analytical processing procedures using step by step checking to assure consistency.

  5. Effect of spark plasma sintering on the microstructure and in vitro behavior of plasma sprayed HA coatings.

    PubMed

    Yu, L-G; Khor, K A; Li, H; Cheang, P

    2003-07-01

    The crystalline phases and degree of crystallinity in plasma sprayed calcium phosphate coatings on Ti substrates are crucial factors that influence the biological interactions of the materials in vivo. In this study, plasma sprayed hydroxyapatite (HA) coatings underwent post-spray treatment by the spark plasma sintering (SPS) technique at 500 degrees C, 600 degrees C, and 700 degrees C for duration of 5 and 30 min. The activity of the HA coatings before and after SPS are evaluated in vitro in a simulated body fluid. The surface microstructure, crystallinity, and phase composition of each coating is characterized by scanning electron microscopy and X-ray diffractometry before, and after in vitro incubation. Results show that the plasma sprayed coatings treated for 5 min in SPS demonstrated increased proportion of beta-TCP phase with a preferred-orientation in the (214) plane, and the content of beta-TCP phase corresponded to SPS temperature, up to 700 degrees C. SPS treatment at 700 degrees C for 30 min enhanced the HA content in the plasma spray coating as well. The HA coatings treated in SPS for 5 min revealed rapid surface morphological changes during in vitro incubation (up to 12 days), indicating that the surface activity is enhanced by the SPS treatment. The thickest apatite layer was found in the coating treated by SPS at 700 degrees C for 5 min.

  6. Sea water corrosion behavior of plasma sprayed abradable coatings

    NASA Astrophysics Data System (ADS)

    Parida, M.; Nanda, S. P.; Mishra, S. C.

    2017-02-01

    Aluminum based abradable coating is used for sealing purpose in compressor casing of aero engines to withstand up to a service temperature of 450°C. Al-BNSiO2 composite coating is deposited using thermal plasma spray technique. Coating thickness measured and porosity of the coating is evaluated.Coating morphology is observed and EDSanalysis is done with SEM (Jeol make). The effect of time on the sea water corrosion behavior of the coating is evaluated. It is observed that, there is a sharp increase in weight gain of the coating up to six weeks of immersion. This behavior is attributed to the adsorption/deposition of other elements/reactions taking place during interaction with sea water.

  7. Failure analysis of plasma-sprayed thermal barrier coatings

    NASA Technical Reports Server (NTRS)

    Berndt, C. C.; Miller, R. A.

    1984-01-01

    Thermally induced failure processes of plasma-sprayed thermal barrier coatings are examined. Cracking processes give rise to noise which was monitored by acoustic emission (AE) techniques. The sequential failure of coatings was examined from samples which were thermally cycled. Coatings of yttria-stabilized zirconia with and without a NiCrAlZr bond coat were plasma-sprayed onto U700 alloy rod. In some cases the substrate was intentionally overheated during deposition of the thermal protection system to check how this process variable influenced the AE response of the specimen. In this way a qualitative appraisal of how process variables affect coating integrity could be discerned in terms of cracking behavior. Results from up to seven consecutive thermal cycles are reported here. Coating failure was observed in all cases. Failure of the thermal protection system is progressive, since cracking and crack growth were observed prior to ultimate failure. Thus castastrophic failure occurs at some stage when there is a transformation from the microcrack to a macrocrack network.

  8. Superhydrophobic Ceramic Coatings by Solution Precursor Plasma Spray

    PubMed Central

    Cai, Yuxuan; Coyle, Thomas W.; Azimi, Gisele; Mostaghimi, Javad

    2016-01-01

    This work presents a novel coating technique to manufacture ceramic superhydrophobic coatings rapidly and economically. A rare earth oxide (REO) was selected as the coating material due to its hydrophobic nature, chemical inertness, high temperature stability, and good mechanical properties, and deposited on stainless steel substrates by solution precursor plasma spray (SPPS). The effects of various spraying conditions including standoff distance, torch power, number of torch passes, types of solvent and plasma velocity were investigated. The as-sprayed coating demonstrated a hierarchically structured surface topography, which closely resembles superhydrophobic surfaces found in nature. The water contact angle on the SPPS superhydrophobic coating was up to 65% higher than on smooth REO surfaces. PMID:27091306

  9. Program for plasma-sprayed self-lubricating coatings

    NASA Technical Reports Server (NTRS)

    Walther, G. C.

    1979-01-01

    A method for preparing composite powders of the three coating components was developed and a procedure that can be used in applying uniform coatings of the composite powders was demonstrated. Composite powders were prepared by adjusting particle sizes of the components and employing a small amount of monoaluminum phosphate as an inorganic binder. Quantitative microscopy (image analysis) was found to be a convenient method of characterizing the composition of the multiphase plasma-sprayed coatings. Area percentages and distribution of the components were readily obtained by this method. The adhesive strength of the coating to a nickel-chromium alloy substrate was increased by about 40 percent by a heat treatment of 20 hours at 650 C.

  10. Characterization of the WC coatings deposited by plasma spraying

    NASA Astrophysics Data System (ADS)

    Benea, M. L.; Benea, L. P.

    2015-06-01

    Tungsten monocarbide (WC) is deposited using a plasma jet on the martensitic noncorrosive steel support (Z12CNDV12), in three different thicknesses.The characteristics of the coatings are determined by: its chemical composition, optical microscopy, RX analysis, tensile adhesion strength, Vickers hardness, the nature and the processing degree of the substrate and the deposition conditions.The method used for determining the behaviour in a corrosive environment of the WC coatings deposited by plasma spraying consists in measuring the electrochemical potential difference between the coating and the substrate, which are immersed in a solution containing NaCl as a corrosive agent. The experimental results are then mathematically processed in order to determine a law and the mechanisms involved.

  11. Plasma sprayed rutile titania-nanosilver antibacterial coatings

    NASA Astrophysics Data System (ADS)

    Gao, Jinjin; Zhao, Chengjian; Zhou, Jingfang; Li, Chunxia; Shao, Yiran; Shi, Chao; Zhu, Yingchun

    2015-11-01

    Rutile titania (TiO2) coatings have superior mechanical properties and excellent stability that make them preferential candidates for various applications. In order to prevent infection arising from bacteria, significant efforts have been focused on antibacterial TiO2 coatings. In the study, titania-nanosilver (TiO2/Ag) coatings with five different kinds of weight percentages of silver nanoparticles (AgNPs) were prepared by plasma spray. The feedstock powders, which had a composition of rutile TiO2 powders containing 1-10,000 ppm AgNPs, were double sintered and deposited on stainless steel substrates with optimized spraying parameters. X-Ray diffraction and scanning electron microscopy were used to analysize the phase composition and surface morphology of TiO2/Ag powders and coatings. Escherichia coli (E. coli) and Staphylococcus aureus (S. aureus) were employed to examine the antibacterial activity of the as-prepared coatings by bacterial counting method. The results showed that silver existed homogeneously in the TiO2/Ag coatings and no crystalline changed happened in the TiO2 structure. The reduction ratios on the TiO2/Ag coatings with 10 ppm AgNPs were as high as 94.8% and 95.6% for E. coli and S. aureus, respectively, and the TiO2/Ag coatings with 100-1000 ppm AgNPs exhibited 100% bactericidal activity against E. coli and S. aureus, which indicated the TiO2/Ag coatings with more than 10 ppm AgNPs had strong antibacterial activity. Moreover, the main factors influencing the antibacterial properties of TiO2/Ag coatings were discussed with grain size and the content of silver as well as the microstructure of the coatings.

  12. Plasma-sprayed metal-glass fluoride coatings for lubrication to 1170 K (1650 F)

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.

    1974-01-01

    Plasma spray of Nichrome matrix composite contains dispersed glass for oxidation protection and calcium fluoride for lubrication. Coatings can be applied to bearing journals and bearing bores. Coating was easily machinable and had excellent bond strength on substrate metal.

  13. A structural investigation of a plasma sprayed Ni--Cr based alloy coating

    SciTech Connect

    Sampath, S.; Neiser, R.A.; Herman, H. ); Kirkland, J.P.; Elam, W.T. )

    1993-01-01

    A Ni--Cr based hardfacing alloy has been plasma sprayed in ambient and low pressure atmospheres onto mild steel substrates. These coatings exhibit excellent wear and corrosion resistance; however, the significance of microstructure on properties has not been reported. This study relates the structure of the sprayed coatings to the processing conditions. X-ray diffraction results indicate phase separation in air plasma sprayed deposits, while low pressure plasma sprayed deposits exhibit a single supersaturated solid solution. Annealing of the air plasma sprayed coating shows dissolution of the bcc chromium phase, confirming its metastable nature. These results were confirmed using Extended X-ray Absorption Fine Structure (EXAFS) analysis, which further suggests a highly disordered structure, with partial oxidation of selected alloying elements, such as chromium. Transmission electron microscopy indicates a wide variety of microstructures in the air plasma sprayed deposit. In the case of low pressure sprayed deposit, the microstructures are homogeneous and uniform.

  14. Deposition of titanium nitride and hydroxyapatite-based biocompatible composite by reactive plasma spraying

    NASA Astrophysics Data System (ADS)

    Roşu, Radu Alexandru; Şerban, Viorel-Aurel; Bucur, Alexandra Ioana; Dragoş, Uţu

    2012-02-01

    Titanium nitride is a bioceramic material successfully used for covering medical implants due to the high hardness meaning good wear resistance. Hydroxyapatite is a bioactive ceramic that contributes to the restoration of bone tissue, which together with titanium nitride may contribute to obtaining a superior composite in terms of mechanical and bone tissue interaction matters. The paper presents the experimental results in obtaining composite layers of titanium nitride and hydroxyapatite by reactive plasma spraying in ambient atmosphere. X-ray diffraction analysis shows that in both cases of powders mixtures used (10% HA + 90% Ti; 25% HA + 75% Ti), hydroxyapatite decomposition occurred; in variant 1 the decomposition is higher compared with the second variant. Microstructure of the deposited layers was investigated using scanning electron microscope, the surfaces presenting a lamellar morphology without defects such as cracks or microcracks. Surface roughness values obtained vary as function of the spraying distance, presenting higher values at lower thermal spraying distances.

  15. Characterizing Suspension Plasma Spray Coating Formation Dynamics through Curvature Measurements

    NASA Astrophysics Data System (ADS)

    Chidambaram Seshadri, Ramachandran; Dwivedi, Gopal; Viswanathan, Vaishak; Sampath, Sanjay

    2016-12-01

    Suspension plasma spraying (SPS) enables the production of variety of microstructures with unique mechanical and thermal properties. In SPS, a liquid carrier (ethanol/water) is used to transport the sub-micrometric feedstock into the plasma jet. Considering complex deposition dynamics of SPS technique, there is a need to better understand the relationships among spray conditions, ensuing particle behavior, deposition stress evolution and resultant properties. In this study, submicron yttria-stabilized zirconia particles suspended in ethanol were sprayed using a cascaded arc plasma torch. The stresses generated during the deposition of the layers (termed evolving stress) were monitored via the change in curvature of the substrate measured using an in situ measurement apparatus. Depending on the deposition conditions, coating microstructures ranged from feathery porous to dense/cracked deposits. The evolving stresses and modulus were correlated with the observed microstructures and visualized via process maps. Post-deposition bi-layer curvature measurement via low temperature thermal cycling was carried out to quantify the thermo-elastic response of different coatings. Lastly, preliminary data on furnace cycle durability of different coating microstructures were evaluated. This integrated study involving in situ diagnostics and ex situ characterization along with process maps provides a framework to describe coating formation mechanisms, process parametrics and microstructure description.

  16. Microstructure and mechanical properties of plasma sprayed HA/YSZ/Ti-6Al-4V composite coatings.

    PubMed

    Khor, K A; Gu, Y W; Pan, D; Cheang, P

    2004-08-01

    Plasma sprayed hydroxyapatite (HA) coatings on titanium alloy substrate have been used extensively due to their excellent biocompatibility and osteoconductivity. However, the erratic bond strength between HA and Ti alloy has raised concern over the long-term reliability of the implant. In this paper, HA/yttria stabilized zirconia (YSZ)/Ti-6Al-4V composite coatings that possess superior mechanical properties to conventional plasma sprayed HA coatings were developed. Ti-6Al-4V powders coated with fine YSZ and HA particles were prepared through a unique ceramic slurry mixing method. The so-formed composite powder was employed as feedstock for plasma spraying of the HA/YSZ/Ti-6Al-4V coatings. The influence of net plasma energy, plasma spray standoff distance, and post-spray heat treatment on microstructure, phase composition and mechanical properties were investigated. Results showed that coatings prepared with the optimum plasma sprayed condition showed a well-defined splat structure. HA/YSZ/Ti-6Al-4V solid solution was formed during plasma spraying which was beneficial for the improvement of mechanical properties. There was no evidence of Ti oxidation from the successful processing of YSZ and HA coated Ti-6Al-4V composite powders. Small amount of CaO apart from HA, ZrO(2) and Ti was present in the composite coatings. The microhardness, Young's modulus, fracture toughness, and bond strength increased significantly with the addition of YSZ. Post-spray heat treatment at 600 degrees C and 700 degrees C for up to 12h was found to further improve the mechanical properties of coatings. After the post-spray heat treatment, 17.6% increment in Young's modulus (E) and 16.3% increment in Vicker's hardness were achieved. The strengthening mechanisms of HA/YSZ/Ti-6Al-4V composite coatings were related to the dispersion strengthening by homogeneous distribution of YSZ particles in the matrix, the good mechanical properties of Ti-6Al-4V and the formation of solid solution among HA

  17. Fabrication and characterization of plasma-sprayed HA/SiO(2) coatings for biomedical application.

    PubMed

    Morks, M F

    2008-01-01

    Fused silica powder has been mixed with hydroxyapatite (HA) powder and plasma sprayed by using gas tunnel-type plasma jet. The influence of silica content (10 wt% and 20 wt%) on the microstructure and mechanical properties of HA-silica coatings was investigated. For investigating the microstructure and mechanical properties of HA-silica coatings, SUS 304 stainless steel was used as substrate material. The spraying was carried out on roughened substrate in an atmospheric chamber. Scanning electron microscope micrographs of cross-sectioned HA/SiO(2) coatings showed that the sprayed HA coatings with 10 and 20 wt% SiO(2) have dense structure with low porosity compared to the pure HA coatings. On the other hand, as the amount of silica was increased the coatings became denser, harder and exhibited high abrasive wear resistance. The presence of silica significantly improved the adhesive strength of HA/SiO(2) coatings mainly due to the increase in bonding strength of the coating at the interface.

  18. Young's Moduli of Cold and Vacuum Plasma Sprayed Metallic Coatings

    NASA Technical Reports Server (NTRS)

    Raj, S. V.; Pawlik, R.; Loewenthal, W.

    2009-01-01

    Monolithic metallic copper alloy and NiCrAlY coatings were fabricated by either the cold spray (CS) or the vacuum plasma spray (VPS) deposition processes. Dynamic elastic modulus property measurements were conducted on these monolithic coating specimens between 300 K and 1273 K using the impulse excitation technique. The Young's moduli decreased almost linearly with increasing temperature at all temperatures except in the case of the CS Cu-23%Cr-5%Al and VPS NiCrAlY, where deviations from linearity were observed above a critical temperature. It was observed that the Young's moduli for VPS Cu-8%Cr were larger than literature data compiled for Cu. The addition of 1%Al to Cu- 8%Cr significantly increased its Young's modulus by 12 to 17% presumably due to a solid solution effect. Comparisons of the Young s moduli data between two different measurements on the same CS Cu- 23%Cr-5%Al specimen revealed that the values measured in the first run were about 10% higher than those in the second run. It is suggested that this observation is due to annealing of the initial cold work microstructure resulting form the cold spray deposition process.

  19. Phase transformation and wear studies of plasma sprayed yttria stabilized zirconia coatings containing various mol% of yttria

    SciTech Connect

    Aruna, S.T. Balaji, N.; Rajam, K.S.

    2011-07-15

    Plasma sprayable grade zirconia powders doped with various mol% of yttria (0, 2, 3, 4, 6, 8 and 12 mol%) were synthesized by a chemical co-precipitation route. The coprecipitation conditions were adjusted such that the powders possessed good flowability in the as calcined condition and thus avoiding the agglomeration step like spray drying. Identical plasma spray parameters were used for plasma spraying all the powders on stainless steel plates. The powders and plasma sprayed coatings were characterized by X-ray diffractometry, Scanning Electron Microscopy and Raman spectroscopy. Zirconia powders are susceptible to phase transformations when subjected to very high temperatures during plasma spraying and XRD is insensitive to the presence of some non crystalline phases and hence Raman spectroscopy was used as an important tool. The microstructure of the plasma sprayed coatings showed a bimodal distribution containing fully melted and unmelted zones. The microhardness and wear resistance of the plasma sprayed coatings were determined. Among the plasma sprayed coatings, 3 mol% yttria stabilized zirconia coating containing pure tetragonal zirconia showed the highest wear resistance. - Research Highlights: {yields} Preparation plasma sprayable YSZ powders without any agglomeration process and plasma spraying {yields} Phase transformation studies of plasma sprayed YSZ coatings by XRD and Raman spectroscopy {yields} Microstructure of the plasma sprayed coatings exhibited bimodal distribution {yields} Plasma sprayed 3 mol% YSZ coating exhibited the highest wear resistance {yields} Higher wear resistance is due to the higher fracture toughness of tetragonal 3 mol% YSZ phase.

  20. Plasma sprayed ceramic thermal barrier coating for NiAl-based intermetallic alloys

    NASA Technical Reports Server (NTRS)

    Miller, Robert A. (Inventor); Doychak, Joseph (Inventor)

    1994-01-01

    A thermal barrier coating system consists of two layers of a zirconia-yttria ceramic. The first layer is applied by low pressure plasma spraying. The second layer is applied by conventional atmospheric pressure plasma spraying. This facilitates the attachment of a durable thermally insulating ceramic coating directly to the surface of a highly oxidation resistant NiAl-based intermetallic alloy after the alloy has been preoxidized to promote the formation of a desirable Al2O3 scale.

  1. Electrocatalytically Active Nickel-Based Electrode Coatings Formed by Atmospheric and Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Aghasibeig, M.; Mousavi, M.; Ben Ettouill, F.; Moreau, C.; Wuthrich, R.; Dolatabadi, A.

    2014-01-01

    Ni-based electrode coatings with enhanced surface areas, for hydrogen production, were developed using atmospheric plasma spray (APS) and suspension plasma spray (SPS) processes. The results revealed a larger electrochemical active surface area for the coatings produced by SPS compared to those produced by APS process. SEM micrographs showed that the surface microstructure of the sample with the largest surface area was composed of a large number of small cauliflower-like aggregates with an average diameter of 10 μm.

  2. Surface characterization and cytotoxicity analysis of plasma sprayed coatings on titanium alloys.

    PubMed

    Rahman, Zia Ur; Shabib, Ishraq; Haider, Waseem

    2016-10-01

    In the realm of biomaterials, metallic materials are widely used for load bearing joints due to their superior mechanical properties. Despite the necessity for long term metallic implants, there are limitations to their prolonged use. Naturally, oxides of titanium have low solubilities and form passive oxide film spontaneously. However, some inclusion and discontinuity spots in oxide film make implant to adopt the decisive nature. These defects heighten the dissolution of metal ions from the implant surface, which results in diminishing bio-integration of titanium implant. To increase the long-term metallic implant stability, surface modifications of titanium alloys are being carried out. In the present study, biomimetic coatings of plasma sprayed hydroxyapatite and titanium were applied to the surface of commercially pure titanium and Ti6Al4V. Surface morphology and surface chemistry were studied using scanning electron microscopy and X-ray photoelectron spectroscopy, respectively. Cyclic potentiodynamic polarization and electrochemical impedance spectroscopy were carried out in order to study their electrochemical behavior. Moreover, cytotoxicity analysis was conducted for osteoblast cells by performing MTS assay. It is concluded that both hydroxyapatite and titanium coatings enhance corrosion resistance and improve cytocompatibility.

  3. Application of Plasma Spraying as a Precursor in the Synthesis of Oxidation-Resistant Coatings

    NASA Astrophysics Data System (ADS)

    Ritt, P.; Lu-Steffes, O.; Sakidja, R.; Perepezko, J. H.; Lenling, W.; Crawmer, D.; Beske, J.

    2013-08-01

    Thermal spray methods offer a versatile and flexible approach to the manufacture of coatings as a final product. A novel application of thermal spray coating is demonstrated by incorporating a plasma-sprayed Mo layer coating as a precursor step within an integrated costing design. The effectiveness of the two-step design is illustrated for aluminoborosilica coatings on SiC/C composites and W substrates based on the plasma-sprayed Mo precursor and subsequent codeposition of Si and B by a pack cementation method. Even with incomplete precursor coverage, an aluminoborosilica coating is developed because of the high initial fluidity of the as-pack coating. An effective oxidation resistance is observed following exposure at elevated temperatures (1373-1673 K) in ambient air and during torch testing at 1773 K, providing clear evidence that the plasma spraying of Mo is a viable precursor step in the formation of the oxidation-resistant Mo-Si-B-based coating.

  4. Technical note - Plasma-sprayed ceramic thermal barrier coatings for smooth intermetallic alloys

    NASA Technical Reports Server (NTRS)

    Miller, R. A.; Doychak, J.

    1992-01-01

    A new approach for plasma spray deposition of ceramic thermal barrier coatings directly to smooth substrates is described. Ceramic thermal barrier coatings were directly applied to substrates that had been coated with low-pressure plasma sprayed NiCrAlY bond coats and then centerless ground to simulate a smooth oxidation-resistant substrate. As the high-temperature oxidation behavior of NiAl+Zr is superior to that of MCrALY alloy, the bond coat is not required for oxidation resistance.

  5. Oxidation and degradation of a plasma-sprayed thermal barrier coating system

    SciTech Connect

    Haynes, J.A.; Ferber, M.K.; Porter, W.D.

    1996-04-01

    The isothermal oxidation behavior of thermal barrier coating (TBC) specimens consisting of single-crystal superalloy substrates, vacuum plasma-sprayed Ni-22Cr-10Al-1Y bond coatings and air plasma-sprayed 7.5 wt.% yttria stabilized zirconia top coatings was evaluated by thermogravimetric analysis at 1150{degrees}C for up to 200 hours. Coating durability was assessed by furnace cycling at 1150{degrees}C. Coatings and reaction products were identified by x-ray diffraction, field-emission scanning electron microscopy and energy dispersive spectroscopy.

  6. Technical note - Plasma-sprayed ceramic thermal barrier coatings for smooth intermetallic alloys

    NASA Astrophysics Data System (ADS)

    Miller, R. A.; Doychak, J.

    1992-09-01

    A new approach for plasma spray deposition of ceramic thermal barrier coatings directly to smooth substrates is described. Ceramic thermal barrier coatings were directly applied to substrates that had been coated with low-pressure plasma sprayed NiCrAlY bond coats and then centerless ground to simulate a smooth oxidation-resistant substrate. As the high-temperature oxidation behavior of NiAl+Zr is superior to that of MCrALY alloy, the bond coat is not required for oxidation resistance.

  7. Isothermal and cyclic oxidation of an air plasma-sprayed thermal barrier coating system

    SciTech Connect

    Haynes, J.A.; Ferber, M.K.; Porter, W.D.; Rigney, E.D.

    1996-08-01

    Thermogravimetric methods for evaluating bond coat oxidation in plasma-sprayed thermal barrier coating (TBC) systems were assessed by high-temperature testing of TBC systems with air plasma-sprayed (APS) Ni-22Cr-10Al-1Y bond coatings and yttria-stabilized zirconia top coatings. High-mass thermogravimetric analysis (at 1150{sup degrees}C) was used to measure bond coat oxidation kinetics. Furnace cycling was used to evaluate APS TBC durability. This paper describes the experimental methods and relative oxidation kinetics of the various specimen types. Characterization of the APS TBCs and their reaction products is discussed.

  8. Life modeling of atmospheric and low pressure plasma-sprayed thermal-barrier coating

    NASA Technical Reports Server (NTRS)

    Miller, R. A.; Argarwal, P.; Duderstadt, E. C.

    1984-01-01

    The cycles-to-failure vs cycle duration data for three different thermal barrier coating systems, which consist of atmospheric pressure plasma-sprayed ZrO2-8 percent Y2O3 over similarly deposited or low pressure plasma sprayed Ni-base alloys, are presently analyzed by means of the Miller (1980) oxidation-based life model. Specimens were tested at 1100 C for heating cycle lengths of 1, 6, and 20 h, yielding results supporting the model's value.

  9. Characterisation of the TiO2 coatings deposited by plasma spraying

    NASA Astrophysics Data System (ADS)

    Benea, M. L.; Benea, L. P.

    2016-02-01

    Plasma spraying of materials such as ceramics and non-metals, which have high melting points, has become a well-established commercial process. Such coatings are increasingly used in aerospace, automobile, textile, medical, printing and electrical industries to impart proprieties such as corrosion resistance, thermal resistance, wear resistance, etc. One of the most important characteristics of thermal barrier coatings is the ability to undergo fast temperature changes without failing, the so called thermal shock resistance. The formation of residual stresses in plasma sprayed ceramic and metallic coatings is a very complex process. Several factors, such as substrate material, substrate thickness, physical properties of both the substrate and the coating material, deposition rate, relative velocity of the plasma torch, etc. determine the final residual stress state of the coating at room temperature. Our objective is to characterize the titanium oxide and aluminium oxide coatings deposited by plasma spraying in structural terms, the resistance to thermal shock and residual stresses.

  10. Morphological Evaluation of Plasma Sprayed Ceramic Coatings using Cavitation Erosion Test

    NASA Astrophysics Data System (ADS)

    Uematsu, Susumu; Tani, Kazumi; Sugasawa, Shinobu; Kawanami, Yasutaka; Namba, Yoshio; Takabatake, Tsuyoshi; Yoshioka, Masaru; Ishihara, Yasuaki

    The microstructure of plasma sprayed ceramic coatings is characterized by the existence of splats along with other morphological features such as interlamellar and globular pores, intrasplat microcracks and splat boundaries. These various process-dependant micro- defects extremely influence physical and mechanical properties such as thermal conductivity and elastic modulus and then influence coating behavior. In this approach, the process involved in the cavitation erosion of plasma sprayed ceramic coatings have been studied using the ultrasonic vibratory technique. The weight loss occurring during fifteen minute intervals of exposure to cavitational erosion was determined, the surface of specimens and the wear debris were examined by Scanning electron microscopy (SEM). The results suggest that the improvement in coating performance could be achieved by controlling the effective contact between lamellae of which the coating is made up using the plasma spray conditions, such as sufficient preheat, short standoff distance and slow gun traversing movement.

  11. Use of plasma sprayed coatings as surface treatments for aluminum adherends

    SciTech Connect

    Davis, G.D.; Whisnant, P.L.; Groff, G.B.

    1996-12-31

    Surface treatments for metal adherends prior to adhesive bonding typically use chromates and/or strong acids and bases. Such materials are hazardous to personnel and harmful to the environment following disposal. To reduce release of these substances into the environment and lower disposal costs, plasma spray treatments are being developed as surface treatments for aluminum adherends. These treatments eliminate liquid and gaseous wastes and provide bond strength and durability comparable to that provided by the conventional chemical treatments. They have other potential advantages of being more suited for repair/refurbishment and less sensitive to metallurgical differences from alloy to alloy. Plasma sprayed coatings are used in a variety of applications where a coating tailored for specific properties is needed that may or may not be chemically or structurally similar to the base substrate. Plasma spraying has been shown to provide excellent high-temperature bond performance with titanium (unlike conventional oxidation treatments) and durability approaching that of phosphoric acid anodization for aluminum. Success has also been reported using other coatings on aluminum, titanium, and steel. Plasma spraying has the important advantage of versatility. A wide range of coatings (metals, ceramics, and polymers) can be deposited onto an equally wide range of substrates, and the coating properties can be optimized for a given application, independent of the substrate. Because of this versatility, plasma-sprayed coatings have been used for wear resistance, thermal barriers, EMI/RF shielding, corrosion resistance, slip/slide resistance, and biocompatibility in addition to adhesion.

  12. New generation of plasma-sprayed mullite coatings on silicon carbide

    NASA Technical Reports Server (NTRS)

    Lee, Kang N.; Miller, Robert A.; Jacobson, Nathan S.

    1995-01-01

    Mullite is promising as a protective coating for silicon-based ceramics in aggressive high-temperature environments. Conventionally plasma-sprayed mullite on SiC tends to crack and debond on thermal cycling. It is shown that this behavior is due to the presence of amorphous mullite in the conventionally sprayed mullite. Heating the SiC substrate during the plasma spraying eliminated the amorphous phase and produced coatings with dramatically improved properties. The new coating exhibits excellent adherence and crack resistance under thermal cycling between room temperature and 1000 to 1400 C. Preliminary tests showed good resistance to Na2CO3-induced hot corrosion.

  13. Fatigue testing of plasma-sprayed thermal barrier coatings, volume 2

    NASA Technical Reports Server (NTRS)

    Cruse, T. A.; Nagy, A.; Popelar, C. F.

    1990-01-01

    A plasma sprayed thermal barrier coating for diesel engines were fatigue tested. Candidate thermal barrier coating materials were fatigue screened and a data base was generated for the selected candidate material. Specimen configurations are given for the bend fatigue tests, along with test setup, specimen preparation, test matrix and procedure, and data analysis.

  14. Efficiency of surface cleaning by a glow discharge for plasma spraying coating

    NASA Astrophysics Data System (ADS)

    Kadyrmetov, A. M.; Kashapov, N. F.; Sharifullin, S. N.; Saifutdinov, A. I.; Fadeev, S. A.

    2016-06-01

    The article presents the results of experimental studies of the quality of cleaning steel surfaces by a glow discharge for plasma spraying. Shows the results of measurements of the angle of surface wetting and bond strength of the plasma coating to the surface treated. The dependence of the influence of the glow discharge power, chamber pressure, distance between the electrodes and the processing time of the surface on cleaning efficiency. Optimal fields of factors is found. It is shown increase joint strength coating and base by 30-80% as a result of cleaning the substrate surface by a glow discharge plasma spraying.

  15. Study on Ceramic Interconnect Manufactured by Slurry Dip Coating and Plasma Spray Coating Processes

    NASA Astrophysics Data System (ADS)

    Lee, Gil-Yong; Kim, Jong-Hee; Ryoo, Sung-Nam; Peck, Dong-Hyun; Jung, Doo-Hwan; Shul, Yong-Gun; Shin, Dong-Ryul; Song, Rak-Hyun

    To get a stable and dense interconnect layer of anode-supported flat tubular solid oxide fuel cell stack, we have studied on the synthesis of precursors with a fine particle size and the ceramic interconnect coating technology. Coated interconnects by slurry dipping and air plasma spray processes were sintered by 2-step sintering method. Ca-doped LaCrO3 perovskites such as La0.75Ca0.27CrO3(LCC27), La0.6Ca0.41CrO3(LCC41), and La0.8Sr0.05Ca0.15CrO3(LSCC), were synthesized by Pechini process and their average particle sizes were about 1 μm. LSCC layer is a functional layer to prevent Ca migration and then LCC41 layer is coated onto it. The Ca migration in the LSCC layer did not occur. The LCC41 was coated on the air plasma spray-coated LCC27 layer by slurry dip coating process and sintered at 1200°C for 20hr. Its electrical conductivity indicated about 27 S/cm at 800°C and the bubble test showed that there is no gas permeation at pressure difference of 0.4 kgf/cm2 at room temperature.

  16. Crack-free surface sealing of plasma sprayed ceramic coatings using an excimer laser

    NASA Astrophysics Data System (ADS)

    Liu, Z.

    2002-01-01

    Yttria stabilized zirconia coatings are typically used in the aerospace industry as high-temperature thermal barriers. These coatings are normally applied by plasma thermal spray, which has an inherent problem of producing coatings containing a substantial amount of open or closed porosity. Surface sealing of plasma sprayed ceramic coatings with CO 2 and Nd:YAG lasers is always associated with the problem of cracking on melted layers. Although some attempts such as pre-heating have been used to overcome the problem, formation of cracking is still not prevented, especially in zirconia-based ceramic coatings. The present work investigates an alternative method of surface sealing of plasma sprayed 8 wt.% Y 2O 3-ZrO 2 coatings using an excimer laser. The results show that smooth, crack-free and crater-free sealing can be obtained. Effects of laser operating parameters on the sealing quality and involved mechanism are also discussed.

  17. Performance of Plasma Sprayed Al2O3 Coating in Bio-Simulated Environment

    NASA Astrophysics Data System (ADS)

    Yıldız, F.; Yetim, A. F.; Alsaran, A.; Çelik, A.

    2014-01-01

    Alumina coatings deposited on the surface of stainless steel 316L by the method of plasma spraying are studied. Tests for wear and corrosion are preformed in Ringer's solution simulating a human body environment. The structure, microhardness, wear resistance and corrosion resistance of the steel are determined with and without a coating. Deposition of a coating onto the stainless steel is shown to be an effective means for protecting implants from corrosion and wear.

  18. Tailored plasma sprayed MCrAlY coatings for aircraft gas turbine applications

    NASA Technical Reports Server (NTRS)

    Pennisi, F. J.; Gupta, D. K.

    1981-01-01

    Eighteen plasma sprayed coating systems, nine based on the NiCoCrAly chemistry and nine based on the CoCrAly composition, were evaluated to identify coating systems which provide equivalent or superior life to that shown by the electron beam physical vapor deposited NiCoCrAly and CoCrAly coatings respectively. NiCoCrAly type coatings were examined on a single crystal alloy and the CoCrAly based coatings were optimized on the B1900+ Hf alloy. Cyclic burner rig oxidation and hot corrosion and tensile ductility tests used to evaluate the various coating candidates. For the single crystal alloy, a low pressure chamber plasma sprayed NiCoCrAly + Si coating exhibited a 2x oxidation life improvement at 1394 K (2050 F) over the vapor deposited NiCoCrAly material while showing equivalent tensile ductility. A silicon modified low pressure chamber plasma sprayed CoCrAly coating was found to be more durable than the baseline vapor deposited CoCrAly coating on the B1900+ Hf alloy.

  19. Fabrication of Nanosized Lanthanum Zirconate Powder and Deposition of Thermal Barrier Coating by Plasma Spray Process

    NASA Astrophysics Data System (ADS)

    Mishra, S. K.; Jagdeesh, N.; Pathak, L. C.

    2016-07-01

    The present manuscript discusses our findings on fabrication of nanosized lanthanum zirconate powder for thermal barrier coating application and its coating by plasma spray on nickel-based superalloy substrate. Single-phase La2Zr2O7 coating of thickness of the order of 45 µm on the Ni-Cr-Al bond coat coated Ni-based superalloy substrate was deposited by plasma spray process. The layers at the interface did not show spallation and inter diffusion was very less. The microstructure, interface, porosity, and mechanical properties of different layers are investigated. The lanthanum zirconate hardness and modulus were 10.5 and 277 GPa, respectively. The load depth curve for lanthanum zirconate showed good elastic recovery around 74%.

  20. Development of improved-durability plasma sprayed ceramic coatings for gas turbine engines

    NASA Technical Reports Server (NTRS)

    Sumner, I. E.; Ruckle, D. L.

    1980-01-01

    An investigation is reported of improving the durability of plasma sprayed ceramic coatings for the vane platforms in the JT9d turbofan engine. The program aims for reduced fuel consumption of commercial aircraft engines; the use of improved strain tolerant microstructures and control of the substrate temperature during coating application are being evaluated. The initial burner rig tests at temperatures up to 1010 C indicated that improvements in cyclic life greater than 20:1 over previous ceramic coatings were achieved. Three plasma sprayed coating systems applied to first stage vane platforms in the high pressure turbine were subjected to a 1000-cycle JT9D engine endurance test with only minor damage occurring to the coatings.

  1. Development of improved-durability plasma sprayed ceramic coatings for gas turbine engines

    NASA Technical Reports Server (NTRS)

    Sumner, I. E.; Ruckle, D. L.

    1980-01-01

    As part of a NASA program to reduce fuel consumption of current commercial aircraft engines, methods were investigated for improving the durability of plasma sprayed ceramic coatings for use on vane platforms in the JT9D turbofan engine. Increased durability concepts under evaluation include use of improved strain tolerant microstructures and control of the substrate temperature during coating application. Initial burner rig tests conducted at temperatures of 1010 C (1850 F) indicate that improvements in cyclic life greater than 20:1 over previous ceramic coating systems were achieved. Three plasma sprayed coating systems applied to first stage vane platforms in the high pressure turbine were subjected to a 100-cycle JT9D engine endurance test with only minor damage occurring to the coatings.

  2. Broadband Plasma-Sprayed Anti-reflection Coating for Millimeter-Wave Astrophysics Experiments

    NASA Astrophysics Data System (ADS)

    Jeong, O.; Lee, A.; Raum, C.; Suzuki, A.

    2016-08-01

    We have developed a plasma-sprayed anti-reflection (AR) coating technology for millimeter-wave astrophysics experiments with cryogenic optics which achieves minimal dissipative loss and broad bandwidth and is easily and accurately applied. Plasma spraying is a coating process through which melted or heated materials are sprayed onto a substrate. The dielectric constants of the plasma-sprayed coatings were tuned between 2.7 and 7.9 by mixing hollow ceramic microspheres with alumina powder as the base material and varying the plasma energy of the spray. By spraying low loss ceramic materials with a tunable dielectric constant, we can apply multiple layers of AR coating for broadband millimeter-wave detection. At 300 K, we achieved a fractional bandwidth of 106 over 90% transmission using a three-layer AR coating. Applying ceramic coatings on ceramic lenses offers an additional benefit of preventing cryogenic delamination of the coatings. We report on methodology of coating application and measurement of uniformity, repeatability, transmission property, and cryogenic adhesion performance.

  3. The effects of plasma spray parameters and atmosphere on the properties and microstructure of WC-Co coatings

    NASA Astrophysics Data System (ADS)

    Ghosh, D.; Lamy, D.; Sopkow, T.; Smuga-Otto, I.

    Wear- and corrosion-resistant coatings deposited by plasma spray process are increasingly used in severe environments in resource industries, such as oil and gas, oil sands, mining, pulp and paper, etc. While there is a large volume of literature in the area of plasma spray coatings, comparatively few papers deal with the co-relation between coating properties and microstructure as a function of plasma spray processing parameters. In this study, the effect of some plasma spray processing variables and atmosphere (air or inert gas) on the microstructure and the properties of WC-Co coatings were studied. The properties of the coatings measured include: microhardness, porosity by image analysis, wear resistance by dry sand/rubber wheel abrasion test (ASTM G 65-91) and corrosion properties by AC impedance technique. Phase analyses of the coatings were also performed by X-ray diffraction. From the above, optimized coatings were developed for oil and gas industry applications.

  4. Processing-microstructure-properties relationships in small-particle plasma-sprayed ceramic coatings

    NASA Astrophysics Data System (ADS)

    Mawdsley, Jennifer Renee

    The objective of this study was to determine processing-microstructure-properties relationships for small-particle plasma-sprayed (SPPS) ceramic coatings. Plasma-sprayed yttria partially-stabilized zirconia (YSZ) coatings, which are used to protect superalloys from heat and the environment in turbine engines, and plasma-sprayed alumina coatings, which are being investigated as a potential replacement for chrome in corrosion protection applications, were fabricated using SPPS technology and their microstructure and pertinent properties were examined. The properties of plasma-sprayed YSZ and alumina coatings were investigated with designed experiments. The parameters varied include power, spray distance, total plasma gas flow, percent hydrogen in the plasma gas, injector angle, injector offset and carrier gas flow. The variations in thermal diffusivity, thermal conductivity, elastic modulus, and hardness for the YSZ SPPS coatings were found to correlate to the variations in density, which were related to the processing variables. It was found that surface roughness was related to the amount of splashing and debris associated with the single splats. In four-point bending strain tolerance and fatigue tests, the SPPS YSZ coatings showed very little acoustic emission activity, except in the case of tensile fatigue of a coating without network cracks. Small angle X-ray scattering experiments revealed that SPPS YSZ coatings have significantly less submicron intersplat porosity than conventional plasma-sprayed coatings, and that the pore and microcrack scattering area decreases with heat treatment due to the sintering of microcracks and small pores. The SPPS alumina coatings were optimized to produce a coating with excellent corrosion protection capabilities. It was found that the hardest SPPS alumina coatings did not provide the best corrosion protection due to unique porosity defect structures associated with surface bumps in the coatings. The surface bumps were

  5. Microstructure and thermal behaviour of plasma sprayed zirconia/alumina composite coating.

    PubMed

    Kobayashi, A; Ando, Y; Kurokawa, K; Hejwowski, T

    2011-10-01

    In thermal barrier coatings (TBC), failure occurs near or at the interface between the metallic bondcoat and topcoat. On high temperature conditions, an oxide scale which is named thermally grown oxide (TGO) occurs along the bond/topcoat interface. For diminishing the creation of TGO, a dense coating with low residual stress and thermal stress buffer layer was preferable. High hardness ceramic coatings could be obtained by gas tunnel type plasma spraying, and the deposited coating had superior property in comparison with those deposited by conventional type plasma spray method. In this study, the gas tunnel type plasma spraying system was utilized to produce a zirconia/alumina functionally graded thermal barrier coating and discussed its physical and mechanical properties, thermal behavior and high temperature oxidation resistance of the coating are discussed. Consequently, the proposed system exhibited superior mechanical properties and oxidation resistance at the expenses of a slightly lower thermal insulating effect. This interlayer is preferred in order to minimize the detrimental effect of the phase transformation of gamma-Al2O3 to alpha-Al2O3.

  6. Relationship Between the Microstructure and Thermal Conductivity of Plasma-Sprayed ZrO2 Coatings

    NASA Astrophysics Data System (ADS)

    Wang, Yongzhe; Wu, Wei; Zheng, Xuebin; Zeng, Yi; Ding, Minju; Zhang, Chenggong

    2011-12-01

    Plasma-sprayed yttria-stabilized zirconia coatings have a complex microstructure consisting of a variety of pores and cracks. These microstructure features which are determined by the spray process are known to influence the thermal conductivity of coatings. In this article, the microstructure features such as total porosity, large pores, and small pores were quantified by means of scanning electron microscopy (SEM) and image analysis, and for each spray process, the particle velocity and particle temperature were measured prior to impact onto the substrate using the online monitoring system (Spray Watch 2i). Multiple linear regression was used to find the relationship between the particle state and the spray gun parameters. The linear regression models were also investigated between the particle state and the microstructure features, in addition, between the microstructure features and the thermal conductivity. The comprehensive correlation of spray process-microstructure-thermal conductivity was established for plasma-sprayed ZrO2 coatings.

  7. Effect of Gun Current on Electrical Properties of Atmospheric Plasma-Sprayed Lanthanum Silicate Coatings

    NASA Astrophysics Data System (ADS)

    Gao, Wei; Liao, Han-Lin; Coddet, Christian

    2013-10-01

    Apatite-type lanthanum silicate (ATLS) electrolyte coatings for use in intermediate-temperature solid oxide fuel cells were deposited by atmospheric plasma spraying (APS). Plasma-sprayed coatings with typical composition La10(SiO4)6O3 exhibiting good densification and high oxide ionic conductivity were obtained by properly adjusting the spraying parameters, particularly the gun current. The highest obtained ionic conductivity value of 3.3 mS/cm at 1,173 K in air is comparable to other ATLS conductors. This work demonstrated empirically that utilization of the APS technique is feasible to synthesize dense La10(SiO4)6O3 electrolyte coatings using gun currents within an unusually broad range.

  8. Microscopic, crystallographic and adherence properties of plasma-sprayed calcium phosphate coatings on Ti-6Al-4V

    NASA Astrophysics Data System (ADS)

    Tufekci, Eser

    Recently, plasma-spayed titanium implants have become very popular in the dentistry because of their biocompatibility and ability of providing osseointegration with the surrounding bone. Although there are numerous published studies on these materials, information and standards are still lacking. This study investigated the miscrostructural, crystallographic and adherence properties of plasma-sprayed hydroxyapatite coatings on Ti-6Al-4V substrates. The microstructures of the coatings and the elemental interdiffusion near the coating/substrate interface were investigated using a scanning electron microscope (SEM) equipped with x-ray energy-dispersive spectroscopy (EDS). X-ray diffraction analyses performed on Ti-6Al-4V coupons prepared with different percent crystallinities have provided structural information such as degree of crystallinity, phases present, average crystallite size, as well as the residual stresses within the coating. For evaluation of the adherence of the coatings to the substrates, experimental rods were subjected to torsion. The fracture surfaces were analyzed using SEM/EDS to develop a new methodology to determine the percent adherence of the coatings. SEM studies indicated that the surface microstructures of commercial dental implants were consistent with the plasma-spraying. In cross-section, coatings exhibited minimal porosity and limited interdiffusion of titanium and calcium at the coating/substrate interface. X-ray diffraction analyses indicated that the highest crystallinity coatings consisted of almost entirely HA and an amorphous calcium phosphate phase. As the coating crystallinity decreased, increasing amounts of alpha- and beta-tricalcium phosphate and tetracalcium phosphate were detected. The mean percent crystallinity for the three sets of coatings ranged from 50-60%. The mean HA crystallite size for the three sets of coatings ranged from about 0.02-0.04 mum. Differences in mean interplanar spacings for three selected

  9. Hydroxyapatite coatings.

    PubMed

    Lacefield, W R

    1988-01-01

    Four coating techniques were evaluated to determine which is most suitable for producing a dense, highly adherent coating onto metallic and ceramic implant materials. Two of the selected coating methods have serious limitations for use in this particular application, and did not meet the specified criteria for satisfactory coating as defined in the initial stages of the study. For example, the dip coating-sintering technique was judged to be unsatisfactory because of the adverse effect of the high-temperature sintering cycle on the mechanical properties of the metallic substrate materials. These materials could not be used in load-bearing applications because of the excessive grain growth and loss of the wrought structure of both the commercially pure Ti and Ti-6Al-4V substrates, and the loss of ductility in the cast Co-Cr-Mo alloy. Another area of concern was that bond strength between the HA coating and the substrate was not high enough to insure that interfacial failure would not occur during the lifetime of the implant. The immersion-coating technique, in which the metal substrate is immersed into the molten ceramic, was shown in a previous study to be the best method of coating a bioreactive glass onto a Co-Cr-Mo implant. Heating HA above its melting temperature, however, caused undesired compositional and structural changes, and upon solidification very limited adherence between the modified ceramic and substrate material occurred under the conditions of this study. The HIP technique, in which the Ti powder substrate and the HA powder coating are sintered together in a high-pressure autoclave, shows great promise for the fabrication of high-quality composite implants. Initial studies have indicated that high-density Ti substrates with a small grain size that are well bonded to a dense HA coating can be produced under optimum conditions. Sintering and densification additives, such as SiO2 powder, do not appear to be necessary. The main drawback to this

  10. The durability of adhesively bonded titanium: Performance of plasma-sprayed polymeric coating pretreatments

    SciTech Connect

    Jackson, F.; Dillard, J.; Dillard, D.

    1996-12-31

    The role of a surface treatment of an adherend is to promote highly stable adhesive-adherend interactions; high stability is accomplished by making the chemistry of the adherend and adhesive compatible. The common surface preparations used to enhance durability include grit blasting, chromic acid or sodium hydroxide anodization, and other chemical treatments for titanium. As interest has grown in the development of environmentally benign surface treatments, other methods have been explored. In this study, plasma-sprayed polymeric materials have been evaluated as a surface coating pretreatment for adhesively bonding titanium alloy. Polyimide and polyether powders were plasm-sprayed onto grit-blasted titanium-6Al-4V. The alloy was adhesively bonded using a high performance polyimide adhesive. The coating was characterized using surface sensitive analytical measurements. The durability performance of the plasma-sprayed adherends was compared to the performance for chromic acid anodized titanium. Among the plasma-sprayed coatings, a LaRC-TPI polyimide-based coating exhibited performance comparable to that for chromic acid anodized specimens.

  11. Recent Trends in Newly Developed Plasma-Sprayed and Sintered Coatings for Implant Applications

    NASA Astrophysics Data System (ADS)

    Bsat, Suzan; Speirs, Andrew; Huang, Xiao

    2016-08-01

    The current paper aims to review recent trends (2011 to 2015) in newly developed plasma-sprayed and sintered coatings for implant applications. Recent developments in plasma-sprayed and sintered coatings have focused on improving biological performance, bacterial growth resistance, and mechanical properties, predominantly of HA and glass ceramics. The majority of these improvements are attributed to the addition of dopants. To improve biological performance, trace elements, such as Zn and Mg, both of which are found in bone, were added to replicate the functions they provide for the skeletal system. Though bacterial growth resistance is traditionally improved by Ag dopant, the addition of new dopants such as CeO2 and Zn were explored as well. Great effort has also been made to improve coating adherence and reduce stresses by minimizing coefficient of thermal expansion mismatch between the coating and substrate through the addition of elements such as Zn and Mg or the inclusion of a buffer layer. For sintering process in particular, there was an emphasis on reducing sintering temperature through modification of 45S5 Bioglass. New plasma spray and sintering technologies aimed at reducing high-temperature exposure are briefly introduced as well. These include microplasma spray and spark plasma sintering.

  12. Effect of laser melting on plasma-sprayed aluminum oxide coatings reinforced with carbon nanotubes

    NASA Astrophysics Data System (ADS)

    Chen, Yao; Samant, Anoop; Balani, Kantesh; Dahotre, Narendra B.; Agarwal, Arvind

    2009-03-01

    The effect of laser melting on the microstructure and mechanical properties of plasma-sprayed aluminum oxide composite coating reinforced with 4 wt% multi-walled carbon nanotubes (CNTs) is reported. Laser-melted layer consists of dense, coarse columnar microstructure which is significantly different from plasma-sprayed coating that consists of splats and porosity. CNTs retained their original cylindrical graphitic structure after undergoing laser irradiation. Three dimensional heat flow model has been developed to estimate temperature variation in the laser-melted composite layer. Laser-melted layers show an increase in the microhardness at the expanse of degradation of fracture toughness. Nanoindentation study indicates an increase in the elastic modulus and yield strength of the laser-melted layer which is attributed to dense microstructure with absence of weak-bonding splats and porosity.

  13. Mechanical Properties of Plasma-Sprayed ZrO2-8 wt% Y2O3 Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Choi, Sung R.; Zhu, Dongming; Miller, Robert A.

    2004-01-01

    Mechanical behavior of free standing, plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings, including strength, fracture toughness, fatigue, constitutive relation, elastic modulus, and directionality, has been determined under various loading-specimen configurations. This report presents and describes a summary of mechanical properties of the plasma-sprayed coating material to provide them as a design database.

  14. Tailoring the heat transfer on the injection moulding cavity by plasma sprayed ceramic coatings

    NASA Astrophysics Data System (ADS)

    Bobzin, K.; Hopmann, Ch; Öte, M.; Knoch, M. A.; Alkhasli, I.; Dornebusch, H.; Schmitz, M.

    2017-03-01

    Inhomogeneous material shrinkage in injection moulding can cause warpage in thermoplastic components. To minimise the deformations of the injection moulding parts, the heat transfer during the cooling phase can be adjusted according to the local cooling demand on the surface of the mould cavity by means of plasma sprayed coatings with locally variable thermal resistance over the surface of the mould. Thermal resistance is a function of thermal conductivity and thickness of the coatings, where thermal conductivity of thermal barrier coatings can be adjusted by altering the chemical composition and the microstructure, which is depending on the thickness. This work evaluates the application of plasma sprayed coatings with variable thickness as thermal barrier coatings in the mould cavity. The thermal resistance of the coating and thereby the heat transfer from the melt into the mould will be influenced locally by varying the coating thickness over the cavity area according to the local cooling demand. Using the laser flash method, the thermal conduction of coatings with different thicknesses will be determined. On the basis of the experimentally determined thermal conduction, the effect of the coatings on the temperature field of the mould cavity will be numerically calculated and the required thickness distribution of the coating for an optimal temperature gradient will be determined.

  15. Sintering and Interface Strain Tolerance of Plasma-Sprayed Thermal and Environmental Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Leissler, George W.; Miller, Robert A.

    2003-01-01

    Ceramic thermal and environmental barrier coatings will be more aggressively designed to protect gas turbine engine hot section SiC/SiC Ceramic Matrix Composite (CMC) components in order to meet future engine higher fuel efficiency and lower emission goals. A coating system consisting of a zirconia-based oxide topcoat (thermal barrier) and a mullite/BSAS silicate inner coat (environmental barrier) is often considered a model system for the CMC applications. However, the coating sintering, and thermal expansion mismatch between the zirconia oxide layer and the silicate environmental barrier/CMC substrate will be of major concern at high temperature and under thermal cycling conditions. In this study, the sintering behavior of plasma-sprayed freestanding zirconia-yttria-based thermal barrier coatings and mullite (and/or barium-strontium-aluminosilicate, i.e., BSAS) environmental barrier coatings was determined using a dilatometer in the temperature range of 1200-1500 C. The effects of test temperature on the coating sintering kinetics were systematically investigated. The plasma-sprayed zirconia-8wt.%yttria and mullite (BSAS) two-layer composite coating systems were also prepared to quantitatively evaluate the interface strain tolerance of the coating system under thermal cycling conditions based on the dilatomentry. The cyclic response of the coating strain tolerance behavior and interface degradation as a function of cycle number will also be discussed.

  16. Latest Researches Advances of Plasma Spraying: From Splat to Coating Formation

    NASA Astrophysics Data System (ADS)

    Fauchais, P.; Vardelle, M.; Goutier, S.

    2016-12-01

    The plasma spray process with solid feedstock, mainly ceramics powders, studied since the sixties is now a mature technology. The plasma jet and particle in-flight characterizations are now well established. The use of computer-aided robot trajectory allows spraying on industrial parts with complex geometries. Works about splat formation have shown the importance of: the substrate preheating over the transition temperature to get rid of adsorbates and condensates, substrate chemistry, crystal structure and substrate temperature during the whole coating process. These studies showed that coating properties strongly depend on the splat formation and layering. The first part of this work deals with a summary of conventional plasma spraying key points. The second part presents the current knowledge in plasma spraying with liquid feedstock, technology developed for about two decades with suspensions of particles below micrometers or solutions of precursors that form particles a few micrometers sized through precipitation. Coatings are finely structured and even nanostructured with properties arousing the interest of researchers. However, the technology is by far more complex than the conventional ones. The main conclusions are that models should be developed further, plasma torches and injection setups adapted, and new measuring techniques to reliably characterize these small particles must be designed.

  17. Remaining Fatigue Life Assessment of Plasma Sprayed Thermal Barrier Coatings

    NASA Astrophysics Data System (ADS)

    Robin, Philippe; Gitzhofer, François; Fauchais, Pierre; Boulos, Maher

    2010-09-01

    Ceramic functional coatings are frequently applied to structural materials, covering a wide range of thermomechanical and electrochemical applications. The main limiting feature is their reliability when subjected to cyclic transient thermal stresses. The study described in this article is a continuation of earlier research study focused on acoustic emission (AE) monitoring of the thermomechanical aging effects in ceramic coatings. Here, emphasis is placed on the usefulness of combining AE short-term monitoring with finite element modeling (FEM) to predict the performance of such coatings when subjected to cyclic thermal loads. The FEM study presented in this article is based on a three-dimensional, time-dependent approach, of the stress fields that developed within the coatings during the post-deposition cooling step and the thermal cycling. Experiments were conducted using yttrium-stabilized zirconia (YSZ) and Alumina (Al2O3) ceramic coatings combined with a NiCr-based intermetallic bond coat.

  18. Preparation of YBa2Cu3O7 High Tc Superconducting Coatings by Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Danroc, J.; Lacombe, J.

    The following sections are included: * INTRODUCTION * THE COMPOUND YBa2Cu3O7-δ * Structure * Critical temperature * Critical current density * Phase equilibria in the YBaCuO system * PREPARATION OF YBa2Cu3O7 COATINGS * General organisation of the preparation process * The powder * Hot plasma spraying of YBa2Cu3O7 * The post-spraying thermal treatment * CHARACTERISTICS OF THE YBa2Cu3O7-δ COATINGS * Chemical composition * Crystalline structure * Morphology of the coatings * Electrical and magnetic characteristics * Conclusion * REFERENCES

  19. Physical, mechanical, and tribological properties of quasicrystalline Al-Cu-Fe coatings prepared by plasma spraying

    NASA Astrophysics Data System (ADS)

    Lepeshev, A. A.; Rozhkova, E. A.; Karpov, I. V.; Ushakov, A. V.; Fedorov, L. Yu.

    2013-12-01

    The physical, mechanical, and tribological properties of quasicrystalline coatings based on the Al65Cu23Fe12 alloy prepared by plasma spraying have been investigated. The specific features of the phase formation due to the competitive interactions of the icosahedral ψ and cubic β phases have been elucidated. A correlation between the microhardness and the content of the icosahedral phase in the coating has been determined. The decisive role of the quasicrystalline phase in the formation of high tribological characteristics of the coatings has been revealed and tested.

  20. Process, properties, and environmental response of plasma sprayed thermal barrier coatings

    NASA Technical Reports Server (NTRS)

    Novak, Richard C.

    1995-01-01

    Experimental results are shown which demonstrate that the properties of plasma sprayed fully stabilized zirconia are strongly influenced by the process parameters. Properties of the coatings in the as-sprayed condition are shown to be additionally influenced by environmental exposure. This behavior is dependent on raw material considerations and processing conditions as well as exposure time and temperature. Process control methodology is described which can take into consideration these complex interactions and help to produce thermal barrier coatings in a cost effective way while meeting coating technical requirements.

  1. Process, properties and environmental response of plasma sprayed thermal barrier coatings

    NASA Technical Reports Server (NTRS)

    Novak, R. C.

    1995-01-01

    Experimental results are shown which demonstrate that the properties of plasma sprayed fully stabilized zirconia are strongly influenced by the process parameters. Properties of the coatings in the as-sprayed condition are shown to be additionally influenced by environmental exposure. This behavior is dependent on raw material considerations and processing conditions as well as exposure time and temperature. Process control methodology is described which can take into consideration these complex interactions and help to produce thermal barrier coatings in a cost effective way while meeting coating technical requirements.

  2. Column formation in suspension plasma-sprayed coatings and resultant thermal properties.

    SciTech Connect

    Van Every, K.; Krane, M. J. M.; Trice, R. W.; Wang, H.; Porter, W.; Besser, M.; Sordelet, D.; Ilavsky, J.; Almer, J.

    2011-06-01

    The suspension plasma spray (SPS) process was used to produce coatings from yttria-stabilized zirconia (YSZ) powders with median diameters of 15 {micro}m and 80 nm. The powder-ethanol suspensions made with 15-{micro}m diameter YSZ particles formed coatings with microstructures typical of the air plasma spray (APS) process, while suspensions made with 80-nm diameter YSZ powder yielded a coarse columnar microstructure not observed in APS coatings. To explain the formation mechanisms of these different microstructures, a hypothesis is presented which relates the dependence of YSZ droplet flight paths on droplet diameter to variations in deposition behavior. The thermal conductivity (k th) of columnar SPS coatings was measured as a function of temperature in the as-sprayed condition and after a 50 h, 1200 C heat treatment. Coatings produced from suspensions containing 80 nm YSZ particles at powder concentrations of 2, 8, and 11 wt.% exhibited significantly different k th values. These differences are connected to microstructural variations between the SPS coatings produced by the three suspension formulations. Heat treatment increased the k th of the coatings generated from suspensions containing 2 and 11 wt.% of 80 nm YSZ powder, but this k th increase was less than has been observed in APS coatings.

  3. Column Formation in Suspension Plasma-Sprayed Coatings and Resultant Thermal Properties

    SciTech Connect

    Van Every, Kent; Krane, Matthew; Trice, Rodney; Wang, Hsin; Porter, Wallace D; Besser, Matthew; Sordelet, Daniel; Ilavsky, Dr. Jan; Almer, Jon

    2011-01-01

    The suspension plasma spray (SPS) process was used to produce coatings from yttria-stabilized zirconia (YSZ) powders with median diameters of 15 {micro}m and 80 nm. The powder-ethanol suspensions made with 15-{micro}m diameter YSZ particles formed coatings with microstructures typical of the air plasma spray (APS) process, while suspensions made with 80-nm diameter YSZ powder yielded a coarse columnar microstructure not observed in APS coatings. To explain the formation mechanisms of these different microstructures, a hypothesis is presented which relates the dependence of YSZ droplet flight paths on droplet diameter to variations in deposition behavior. The thermal conductivity (k th) of columnar SPS coatings was measured as a function of temperature in the as-sprayed condition and after a 50 h, 1200 C heat treatment. Coatings produced from suspensions containing 80 nm YSZ particles at powder concentrations of 2, 8, and 11 wt.% exhibited significantly different k th values. These differences are connected to microstructural variations between the SPS coatings produced by the three suspension formulations. Heat treatment increased the k th of the coatings generated from suspensions containing 2 and 11 wt.% of 80 nm YSZ powder, but this k th increase was less than has been observed in APS coatings.

  4. Nano Structured Plasma Spray Coating for Wear and High Temperature Corrosion Resistance Applications

    NASA Astrophysics Data System (ADS)

    Ghosh, D.; Shukla, A. K.; Roy, H.

    2014-04-01

    The nano structured coating is a major challenge today to improve the different mechanical properties, wear and high temperature corrosion resistance behaviour of different industrial alloys. This paper is a review on synthesis of nano powder, plasma spraying methods, techniques of nano structured coating by plasma spray method, mechanical properties, tribological properties and high temperature corrosion behaviour of nano structured coating. Nano structured coatings of ceramic powders/composites are being developed for wide variety of applications like boiler, turbine and aerospace industries, which requires the resistance against wear, corrosion, erosion etc. The nano sized powders are subjected to agglomeration by spray drying, after which nano structured coating can be successfully applied over the substrate. Nano structured coating shows improved mechanical wear resistance and high temperature corrosion resistance. The significant improvement of wear and corrosion resistance is mainly attributed to formation of semi molten nano zones in case of nano structured coatings. The future scope of application of nano structured coating has also been highlighted in this paper.

  5. Fabrication and Wear Behavior of Nanostructured Plasma-Sprayed 6061Al-SiCp Composite Coating

    NASA Astrophysics Data System (ADS)

    Tailor, Satish; Mohanty, R. M.; Sharma, V. K.; Soni, P. R.

    2014-10-01

    6061Al powder with 15 wt.% SiC particulate (SiCp) reinforcement was mechanically alloyed (MA) in a high-energy attrition mill. The MA powder was then plasma sprayed onto weathering steel (Cor-Ten A242) substrate using an atmospheric plasma spray process. Results of particle size analysis and scanning electron microscopy show that the addition of SiC particles as the reinforcement influences on the matrix grain size and morphology. XRD studies revealed embedment of SiCp in the MA-processed composite powder, and nanocrystals in the MA powder and the coating. Microstructural studies showed a uniform distribution of reinforced SiC particles in the coating. The porosity level in the coating was as low as 2% while the coating hardness was increased to 232VHN. The adhesion strength of the coatings was high and this was attributed to higher degree of diffusion at the interface. The wear rate in the coatings was evaluated using a pin-on-disk type tribometer and found to decrease by 50% compared to the 6061Al matrix coating. The wear mechanism in the coating was delamination and oxidative type.

  6. Monitoring Delamination of Plasma-Sprayed Thermal Barrier Coatings by Reflectance-Enhanced Luminescence

    NASA Technical Reports Server (NTRS)

    Eldridge, Jeffrey I.; Bencic, Timothy J.

    2006-01-01

    Highly scattering plasma-sprayed thermal barrier coatings (TBCs) present a challenge for optical diagnostic methods to monitor TBC delamination because scattering attenuates light transmitted through the TBC and usually degrades contrast between attached and delaminated regions of the TBC. This paper presents a new approach where reflectance-enhanced luminescence from a luminescent sublayer incorporated along the bottom of the TBC is used to identify regions of TBC delamination. Because of the higher survival rate of luminescence reflecting off the back surface of a delaminated TBC, the strong scattering exhibited by plasma-sprayed TBCs actually accentuates contrast between attached and delaminated regions by making it more likely that multiple reflections of luminescence off the back surface occur before exiting the top surface of the TBC. A freestanding coating containing sections designed to model an attached or delaminated TBC was prepared by depositing a luminescent Eu-doped or Er-doped yttria-stabilized zirconia (YSZ) luminescent layer below a plasma-sprayed undoped YSZ layer and utilizing a NiCr backing layer to represent an attached substrate. For specimens with a Eu-doped YSZ luminescent sublayer, luminescence intensity maps showed excellent contrast between unbacked and NiCr-backed sections even at a plasma-sprayed overlayer thickness of 300 m. Discernable contrast between unbacked and NiCr-backed sections was not observed for specimens with a Er-doped YSZ luminescent sublayer because luminescence from Er impurities in the undoped YSZ layer overwhelmed luminescence originating form the Er-doped YSZ sublayer.

  7. Reactive Plasma-Sprayed Aluminum Nitride-Based Coating Thermal Conductivity

    NASA Astrophysics Data System (ADS)

    Shahien, Mohammed; Yamada, Motohiro; Fukumoto, Masahiro; Egota, Kazumi; Okamoto, Kenji

    2015-12-01

    Recently, thick aluminum nitride/alumina (AlN/Al2O3) composite coatings were successfully fabricated through the reactive plasma spraying of fine Al2O3/AlN mixture in the N2/H2 atmospheric plasma. The coatings consist of AlN, Al5O6N, γ-Al2O3, and α-Al2O3 phases. This study will evaluate the thermal conductivity of these complicated plasma-sprayed coatings and optimize the controlling aspects. Furthermore, the influence of the process parameters on the coatings thermal conductivity will be investigated. The fabricated coatings showed very low thermal conductivity (2.43 W/m K) compared to the AlN sintered compacts. It is attributed to the phase composition of the fabricated coatings, oxide content, and porosity. The presence of Al2O3, Al5O6N and the high coating porosity decreased its thermal conductivity. The presence of oxygen in the AlN lattice creates Al vacancies which lead to phonon scattering and therefore suppressed the thermal conductivity. The formation of γ-Al2O3 phase in the coating leads to further decrease in its conductivity, due to its lower density compared to the α-phase. Moreover, the high porosity of the coating strongly suppressed the conductivity. This is due to the complicated microstructure of plasma spray coatings (splats, porosity, and interfaces, particularly in case of reactive spray process), which obviously lowered the conductivity. Furthermore, the measured coating density was lower than the AlN value and suppressed the coating conductivity. In addition, the spraying parameter showed a varied effect on the coating phase composition, porosity, density, and therefore on its conductivity. Although the N2 gas flow improved the nitride content, it suppressed the thermal conductivity gradually. It is attributed to the further increase in the porosity and further decrease in the density of the coatings with the N2 gas. Furthermore, increasing the arc did not show a significant change on the coating thermal conductivity. On the other hand

  8. Plasma-Sprayed Hydroxylapatite-Based Coatings: Chemical, Mechanical, Microstructural, and Biomedical Properties

    NASA Astrophysics Data System (ADS)

    Heimann, Robert B.

    2016-06-01

    This contribution discusses salient properties and functions of hydroxylapatite (HA)-based plasma-sprayed coatings, including the effect on biomedical efficacy of coating thickness, phase composition and distribution, amorphicity and crystallinity, porosity and surface roughness, cohesion and adhesion, micro- and nano-structured surface morphology, and residual coating stresses. In addition, it will provide details of the thermal alteration that HA particles undergo in the extremely hot plasma jet that leads to dehydroxylated phases such as oxyhydroxylapatite (OHA) and oxyapatite (OA) as well as thermal decomposition products such as tri-(TCP) and tetracalcium phosphates (TTCP), and quenched phases such as amorphous calcium phosphate (ACP). The contribution will further explain the role of ACP during the in vitro interaction of the as-deposited coatings with simulated body fluid resembling the composition of extracellular fluid (ECF) as well as the in vivo responses of coatings to the ECF and the host tissue, respectively. Finally, it will briefly describe performance profiles required to fulfill biological functions of osteoconductive bioceramic coatings designed to improve osseointegration of hip endoprostheses and dental root implants. In large parts, the content of this contribution is a targeted review of work done by the author and his students and coworkers over the last two decades. In addition, it is considered a stepping stone toward a standard operation procedure aimed at depositing plasma-sprayed bioceramic implant coatings with optimum properties.

  9. Evaluation of hot corrosion of 8YSZ coatings elaborated by suspension plasma spraying

    NASA Astrophysics Data System (ADS)

    González-Hernández, A. G.; Ageorges, H.; López-Gómez, M. E.

    2017-01-01

    In this paper, the evaluation microscopic of hot corrosion of 8mol% Yttria Stabilized Zirconia (8YSZ) coatings was studied in the presence of V2O5 and Na2SO4 as corrosive molten salt, for 40h at 1050°C. First, the substrates of Inconel 718 super-alloy were sprayed with a NiCrCoAl-Y2O3 bond coat by atmospheric plasma spraying (APS). Then this bond coat was polished for elaborated the 8YSZ layer by suspension plasma spraying (SPS). The microstructure of the cross-section and surface of the coating was evaluated by scanning electron microscopy (SEM). After the hot corrosion test, the delamination of 8YSZ coatings was occurred in the ceramic layer due to the creation of stress resulting from the chemical reaction between the molten salts and the yttria (Y2O3) of 8YSZ coating at high temperature. According to EDS-SEM analysis, the evaluation of fractured sections of 8YSZ coating showed mainly the formation of crystals composed by Y, V, O and the surface was mainly composed by Zr and O. Those crystals can be related with the tetragonal phase of YVO4, which they were commonly found by other researchers in studies of hot corrosion of YSZ-based TBCs when its surface reacts with the corrosive salts.

  10. Tribological Characterization of Plasma-Sprayed CoNiCrAlY-BN Abradable Coatings

    NASA Astrophysics Data System (ADS)

    Irissou, E.; Dadouche, A.; Lima, R. S.

    2014-01-01

    The processing conditions, microstructural and tribological characterizations of plasma-sprayed CoNiCrAlY-BN high temperature abradable coatings are reported in this manuscript. Plasma spray torch parameters were varied to produce a set of abradable coatings exhibiting a broad range of porosity levels (34-62%) and superficial Rockwell hardness values (0-78 HR15Y). Abradability tests have been performed using an abradable-seal test rig, capable of simulating operational wear at different rotor speeds and seal incursion rates (SIRs). These tests allowed determining the rubbing forces and quantifying the blade and seal wear characteristics for slow and fast SIRs. Erosion wear performance and ASTM C633 coating adhesion strength test results are also reported. For optimal abradability performance, it is shown that coating hardness needs to be lower than 70 and 50 HR15Y for slow and fast blade incursion rate conditions, respectively. It is shown that the erosion wear performance, as well as, the coating cohesive strength is a function of the coating hardness. The current results allow defining the coating specifications in terms of hardness and porosity for targeted applications.

  11. Plasma Spray-Physical Vapor Deposition (PS-PVD) of Ceramics for Protective Coatings

    NASA Technical Reports Server (NTRS)

    Harder, Bryan J.; Zhu, Dongming

    2011-01-01

    In order to generate advanced multilayer thermal and environmental protection systems, a new deposition process is needed to bridge the gap between conventional plasma spray, which produces relatively thick coatings on the order of 125-250 microns, and conventional vapor phase processes such as electron beam physical vapor deposition (EB-PVD) which are limited by relatively slow deposition rates, high investment costs, and coating material vapor pressure requirements. The use of Plasma Spray - Physical Vapor Deposition (PS-PVD) processing fills this gap and allows thin (< 10 microns) single layers to be deposited and multilayer coatings of less than 100 microns to be generated with the flexibility to tailor microstructures by changing processing conditions. Coatings of yttria-stabilized zirconia (YSZ) were applied to NiCrAlY bond coated superalloy substrates using the PS-PVD coater at NASA Glenn Research Center. A design-of-experiments was used to examine the effects of process variables (Ar/He plasma gas ratio, the total plasma gas flow, and the torch current) on chamber pressure and torch power. Coating thickness, phase and microstructure were evaluated for each set of deposition conditions. Low chamber pressures and high power were shown to increase coating thickness and create columnar-like structures. Likewise, high chamber pressures and low power had lower growth rates, but resulted in flatter, more homogeneous layers

  12. Effect of Porosity on Photocatalytic Activity of Plasma-Sprayed TiO2 Coating

    NASA Astrophysics Data System (ADS)

    Zhang, Cheng; Chaudhary, Ujwal; Das, Santanu; Godavarty, Anuradha; Agarwal, Arvind

    2013-10-01

    The effect of porosity on photocatalytic activity of plasma-sprayed TiO2 coating on steel substrate is studied by varying processing parameters viz. plasma power and powder feed rate. The relationship between porosity content and methylene blue (MB) dye decomposition rate was established to correlate coating microstructure and its photocatalytic activity. The coating with the highest porosity content exhibited best photocatalytic efficiency. The same processing parameters were used to deposit TiO2 coating on FTO glass. The photocatalytic activity of TiO2 coating on FTO was 2.5 times better than TiO2 coating on the steel substrate. TiO2 coating on FTO glass contains bimodal porosity distribution (micropores and submicron pores) which accelerated MB decomposition by accelerated diffusion of ionic species.

  13. Wide-temperature-spectrum self-lubricating coatings prepared by plasma spraying

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.

    1979-01-01

    Self-lubricating, multicomponent coatings, which lubricate over a wide range of operating conditions, are described. The coatings were successfully applied by plasma-spraying mixed powders onto superalloy substrates. They were evaluated in friction and wear experiments, and in sliding contact bearing tests. These coatings are wear resistant by virtue of their self lubricating characteristics rather than because of extreme hardness; a further benefit is low friction. Experiments with simple pin on disk sliding specimens and oscillating plain cylindrical bearing tests were performed to evaluate the tribological properties of the coatings. It was shown that coatings of nichrome, glass and calcium fluoride are self-lubricating from about 500 to 900 C, but give high friction at the lower temperatures. The addition of silver to the coating composition improved the low temperature bearing properties and resulted in coatings which are self-lubricating from cryogenic temperatures to at least 870 C; they are therefore, wide temperature spectrum, self-lubricating compositions.

  14. Characterization of Microstructure and Thermal Properties of YSZ Coatings Obtained by Axial Suspension Plasma Spraying (ASPS)

    NASA Astrophysics Data System (ADS)

    Ganvir, Ashish; Curry, Nicholas; Björklund, Stefan; Markocsan, Nicolaie; Nylén, Per

    2015-10-01

    The paper aims at demonstrating various microstructures which can be obtained using the suspension spraying technique and their respective significance in enhancing the thermal insulation property of a thermal barrier coating. Three different types of coating microstructures are discussed which were produced by the Axial Suspension Plasma Spraying. Detailed characterization of coatings was then performed. Optical and scanning electron microscopy were utilized for microstructure evaluations; x-ray diffraction for phase analysis; water impregnation, image analysis, and mercury intrusion porosimetry for porosity analysis, and laser flash analysis for thermal diffusivity measurements were used. The results showed that Axial Suspension Plasma Spraying can generate vertically cracked, porous, and feathery columnar-type microstructures. Pore size distribution was found in micron, submicron, and nanometer range. Higher overall porosity, the lower density of vertical cracks or inter-column spacing, and higher inter-pass porosity favored thermal insulation property of the coating. Significant increase in thermal diffusivity and conductivity was found at higher temperature, which is believed to be due to the pore rearrangement (sintering and pore coarsening). Thermal conductivity values for these coatings were also compared with electron beam physical vapor deposition (EBPVD) thermal barrier coatings from the literature and found to be much lower.

  15. Suspension Plasma Spraying of Sub-micron Silicon Carbide Composite Coatings

    NASA Astrophysics Data System (ADS)

    Mubarok, F.; Espallargas, N.

    2015-06-01

    Thermal spraying of silicon carbide (SiC) material is a challenging task since SiC tends to decompose during atmospheric spraying process. The addition of metal or ceramic binders is necessary to facilitate the bonding of SiC particles, allowing SiC composite coating to be deposited. In the conventional procedures, the binders are added through mechanical mixing of powder constituents, making it difficult to achieve homogeneous distribution. In the new procedure proposed in this work, the binder is delivered as a nano-film of the surface of the individual SiC particles through co-precipitation treatment. Suspension plasma spray (SPS) coating technique has been used with the aim at avoiding the decomposition of SiC typically expected with atmospheric techniques, such as atmospheric plasma spray. The deposited SiC coatings by SPS showed identical SiC phase peak as identified in the suspension feedstock, indicating that the nano-film binder was able to protect SiC particles from decomposition. Further analysis by XPS revealed that SiC particles underwent some minor oxidation. Unfortunately, all the SiC coatings exhibited poor mechanical performance due to low cohesive strength, high porosity, and powdery structure making the coatings vulnerable to grain pull-out. This was due to the absence of sintering process during the spraying process contributing to the low performance of SiC SPS coatings.

  16. Microwave absorption property of plasma spray W-type hexagonal ferrite coating

    NASA Astrophysics Data System (ADS)

    Wei, Shicheng; Liu, Yi; Tian, Haoliang; Tong, Hui; Liu, Yuxin; Xu, Binshi

    2015-03-01

    In order to enhance the adhesion strength of microwave absorbing materials, W-type hexagonal ferrite coating is fabricated by plasma spray. The feedstock of ferrite powders is synthesized by solid-state reaction and spray dried process. Microstructures of the coating are analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive spectra (EDS). Hexagonal ferrite coating is successfully deposited on the substrate with adhesion strength of 28 MPa. The magnetic property of ferrite samples is measured using vibrating sample magnetometer (VSM). Saturation magnetization of the ferrite coating is lower than ferrite powder. Reflection loss of the hexagonal ferrite coating is measured in frequency of 2-18 GHz. The result shows that the coating is suitable for electromagnetic wave absorbers in Ku-band.

  17. Electrochemical Impedance Studies on Tribocorrosion Behavior of Plasma-Sprayed Al2O3 Coatings

    NASA Astrophysics Data System (ADS)

    Liu, Zhe; Chu, Zhenhua; Chen, Xueguang; Dong, Yanchun; Yang, Yong; Li, Yingzhen; Yan, Dianran

    2015-06-01

    In this paper, the tribocorrosion of plasma-sprayed Al2O3 coatings in simulated seawater was investigated by electrochemical impedance spectroscopy (EIS) technique, complemented by scanning electron microscopy to observe the morphology of the tribocorrosion attack. Base on EIS of plasma-sprayed Al2O3 coatings undergoing long-time immersion in simulated seawater, the corrosion process of Al2O3 coatings can be divided into the earlier stage of immersion (up to 20 h) and the later stage (beyond 20 h). Then, the wear tests were carried out on the surface of Al2O3 coating undergoing different times of immersion to investigate the influence of wear on corrosion at different stages. The coexistence of wear and corrosion condition had been created by a boron nitride grinding head rotating on the surface of coatings corroded in simulated seawater. The measured EIS and the values of the fitting circuit elements showed that wear accelerated corrosion at the later stage, meanwhile, corrosion accelerated wear with the immersion time increasing.

  18. Mathematical analysis of thermoelastic characteristics in plasma-sprayed thermal barrier coatings.

    PubMed

    Go, Jaegwi; Jungo, Yeon-Gil; Kim, Seokchan; Ali, Md Afsar; Paik, Ungyu

    2012-02-01

    The thermoelastic characteristics of plasma-sprayed thermal barrier coatings (TBCs) have been analyzed using mathematical modeling. Two types of TBC model, cylinder and circular disk which are commercial plasma-sprayed TBCs, subjecting to symmetric temperature distribution to the radial and longitudinal directions, respectively, were taken into consideration. Based on the thermoelastic theories, a second order ordinary differential equation was derived for the cylinder model and a pair of partial differential equations were set up for the circular disk model. The analytic solution was obtained from the ordinary differential equation, while a finite volume method was developed for numerical solutions to the pair of partial differential equations due to the complexity of governing equations. The thermoelastic characteristics of TBC models, such as temperature distributions, displacements, and stresses, were displayed according to the obtained solutions. The rate of heat conduction in the section of the top coat is relatively slow in comparison with the substrate, and no profound difference appears in the temperature distribution between two TBC models. The highest longitudinal tensile stress is expressed at the bond coat of both models, and the substrate is under the compressive stresses to the circumferential direction. While the cylinder expands to the positive longitudinal direction only, the expansion in the circular disk occurs to both the positive and negative longitudinal directions. Relatively large displacement and stresses exhibit in the cylinder as compared with the circular disk. In the circular disk, the stresses to the radial direction undulate at each section, and the displacement profile displays that the width of the circular disk is slightly narrowed. The results demonstrate that the mechanical and thermal properties of the top and bond coats are the crucial factors to be considered in controlling the thermoelastic characteristics of plasma-sprayed

  19. A design of experiment study of plasma sprayed alumina-titania coatings

    SciTech Connect

    Steeper, T.J.; Varacalle, D.J. Jr.; Wilson, G.C.; Riggs, W.L. II; Rotolico, A.J.; Nerz, J.E.

    1992-08-01

    An experimental study of the plasma spraying of alumina-titania powder is presented in this paper. This powder system is being used to fabricate heater tubes that emulate nuclear fuel tubes for use in thermal-hydraulic testing. Coating experiments were conducted using a Taguchi fractional-factorial design parametric study. Operating parameters were varied around the typical spray parameters in a systematic design of experiments in order to display the range of plasma processing conditions and their effect on the resultant coating. The coatings were characterized by hardness and electrical tests, image analysis, and optical metallography. Coating qualities are discussed with respect to dielectric strength, hardness, porosity, surface roughness, deposition efficiency, and microstructure. The attributes of the coatings are correlated with the changes in operating parameters.

  20. Neutron and X-ray diffraction of plasma-sprayed zirconia-yttria thermal barrier coatings

    NASA Technical Reports Server (NTRS)

    Shankar, N. R.; Herman, H.; Singhal, S. P.; Berndt, C. C.

    1984-01-01

    ZrO2-7.8mol. pct. YO1.5, a fused powder, and ZrO2-8.7mol. pct. YO1.5, a prereacted powder, were plasma-sprayed onto steel substrates. Neutron diffraction and X-ray diffraction of the as-received powder, the powder plasma sprayed into water, as-sprayed coatings, and coatings heat-treated for 10 and 100 h were carried out to study phase transformations and ordering of the oxygen ions on the oxygen sublattice. The as-received fused powder has a much lower monoclinic percentage than does the pre-reacted powder, this resulting in a much lower monoclinic percentage in the coating. Heat treatment increases the percentages of the cubic and monoclinic phases, while decreasing the tetragonal content. An ordered tetragonal phase is detected by the presence of extra neutron diffraction peaks. These phase transformations and ordering will result in volume changes. The implications of these transformations on the performance of partially stabilized zirconia thermal barrier coatings is discussed.

  1. Columnar-Structured Mg-Al-Spinel Thermal Barrier Coatings (TBCs) by Suspension Plasma Spraying (SPS)

    NASA Astrophysics Data System (ADS)

    Schlegel, N.; Ebert, S.; Mauer, G.; Vaßen, R.

    2015-01-01

    The suspension plasma spraying (SPS) process has been developed to permit the feeding of sub-micrometer-sized powder into the plasma plume. In contrast to electron beam-physical vapor deposition and plasma spray-physical vapor deposition, SPS enables the cost-efficient deposition of columnar-structured coatings. Due to their strain tolerance, these coatings play an important role in the field of thermal barrier coatings (TBCs). In addition to the cost-efficient process, attention was turned to the TBC material. Nowadays, yttria partially stabilized zirconia (YSZ) is used as standard TBC material. However, its long-term application at temperatures higher than 1200 °C is problematic. At these high temperatures, phase transitions and sintering effects lead to the degradation of the TBC system. To overcome those deficits of YSZ, Mg-Al-spinel was chosen as TBC material. Even though it has a lower melting point (~2135 °C) and a higher thermal conductivity (~2.5 W/m/K) than YSZ, Mg-Al-spinel provides phase stability at high temperatures in contrast to YSZ. The Mg-Al-spinel deposition by SPS resulted in columnar-structured coatings, which have been tested for their thermal cycling lifetime. Furthermore, the influence of substrate cooling during the spraying process on thermal cycling behavior, phase composition, and stoichiometry of the Mg-Al-spinel has been investigated.

  2. Thermal Shock Properties of Yttria-Stabilized Zirconia Coatings Deposited Using Low-Energy Very Low Pressure Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Zhu, Lin; Zhang, Nannan; Bolot, Rodolphe; Liao, Hanlin; Coddet, Christian

    2015-08-01

    Yttria-stabilized zirconia (YSZ) coatings have been frequently used as a thermal protective layer on the metal or alloy component surfaces. In the present study, ZrO2-7%Y2O3 thermal barrier coatings (TBCs) were successfully deposited by DC (direct current) plasma spray process under very low pressure conditions (less than 1 mbar) using low-energy plasma guns F4-VB and F100. The experiments were performed to evaluate the thermal shock resistance of different TBC specimens which were heated to 1373 K at a high-temperature cycling furnace and held for 0.5 h, followed by air cooling at room temperature for 0.2 h. For comparison, a corresponding atmospheric plasma spray (APS) counterpart was also elaborated to carry out the similar experiments. The results indicated that the very low pressure plasma spray (VLPPS) coatings displayed better thermal shock resistance. Moreover, the failure mechanism of the coatings was elucidated.

  3. Effect of plasma spraying regimes on structure and properties of Ni3Al coatings

    NASA Astrophysics Data System (ADS)

    Kornienko, E. E.; Mul', D. O.; Rubtsova, O. A.; Vaschenko, S. P.; Kuzmin, V. I.; Gulyaev, I. P.; Sergachev, D. V.

    2016-11-01

    The structure and tribological properties of coatings made of PN85YU15 powder were studied. The coatings were deposited on the mild steel blanks by the technology of air-plasma spraying using a unit of annular input and gas-dynamic powder focusing. Efficiency of heating and acceleration of powder particles was studied preliminarily. Measurement results on temperature and velocity distributions of particles at a certain spraying distance by the method of spectral pyrometry and time-of-flight method are presented. The effect of plasmatorch arc current and amount of propane-butane in the plasma flow on the structure and properties of coatings is analyzed in this paper. It is determined that the phase composition of coatings and initial powder is the same: the main phase is Ni3Al compound; moreover, the structure contains Ni5Al3 phase. It is shown that an increase in the amount of propane-butane increases coatings porosity. The densest coatings (5.77%) were obtained at the plasmatorch arc current of 200 A with the reduced amount of propane-butane. The coatings obtained at the minimal arc current of 100 A with an increased amount of propane-butane are characterized by maximal porosity (20.38%). The results of tribological testing of the coatings under the conditions of sliding friction with a lubricant by the disc-plane scheme are presented. From the standpoint of obtaining the densest coatings with high performance, the optimal regimes of plasma spraying of PN85YU15 powder are the current from 140 A to 200 and using the air and propane-butane mixture only as the shielding gas (anode curtain).

  4. Chemical Phase and Valence Studies of Plasma Sprayed Coatings: EDXRD and X-ray Absorption Spectroscopy (XAS) Results

    DTIC Science & Technology

    2010-06-01

    Versatile XAS micro-(NSLS)/nano(NSLS-II)- probe: local mapping of structure chemistry Rare Earth (RE) 4f -localized atomic, core states** Ce Problem and Ce-L3...powder • Ce3+ n-PS coating Ce4+O2 Ce 3+ !!!!!! PS Plasma Spray Chemical reduction of Ce Average Ce-O distance estimate Rare Earth continuum...local ligand coordination - structure EDXRD: plasma sprayed alumina-titania coatings (on Ti-6-4) • nATCZ → nano composite alumina-titania coating

  5. Nanocomposite Lanthanum Zirconate Thermal Barrier Coating Deposited by Suspension Plasma Spray Process

    NASA Astrophysics Data System (ADS)

    Wang, Chaohui; Wang, You; Wang, Liang; Hao, Guangzhao; Sun, Xiaoguang; Shan, Fan; Zou, Zhiwei

    2014-10-01

    This work seeks to develop an innovative nanocomposite thermal barrier coating (TBC) exhibiting low thermal conductivity and high durability compared with that of current TBCs. To achieve this objective, nanosized lanthanum zirconate particles were selected for the topcoat of the TBC system, and a new process—suspension plasma spray—was employed to produce desirable microstructural features: the nanocomposite lanthanum zirconate TBC contains ultrafine splats and high volume porosity, for lower thermal conductivity, and better durability. The parameters of plasma spray experiment included two main variables: (i) spray distance varying from 40 to 80 mm and (ii) the concentration of suspension 20, 25, and 30 wt.%, respectively. The microstructure of obtained coatings was characterized with scanning electron microscope and x-ray diffraction. The porosity of coatings is in the range of 6-10%, and the single phase in the as-sprayed coatings was pyrochlore lanthanum zirconate.

  6. Influence of Laser Glazing on the Characterization of Plasma-Sprayed YSZ Coatings

    NASA Astrophysics Data System (ADS)

    Wang, Yan; Liu, Jiangwei; Liao, Hanlin; Darut, Geoffrey; Stella, Jorge; Poirier, Thierry; Planche, Marie-Pierre

    2017-01-01

    In this study, 8 wt.% yttria-stabilized zirconia powder was deposited on the substrates by atmospheric plasma spray. The coatings were post-treated by laser glazing under different parameters in order to densify them. The characterization of the laser molten pools under different laser treatment conditions was studied. Preheating processes were also employed. Scanning electron microscopy observations of the surface and cross section of as-sprayed and laser-glazed coatings were carried out to investigate the influence of laser glazing on the microstructure on laser-glazed coatings. The results show that preheating processes improve the coating in terms of deepening the laser-glazed layer, reducing the number of vertical cracks and surface density of cracks and widening the molten pool. Finally, the influences of linear energy density on the characterization of the glazed layer are discussed.

  7. Plasma sprayed coatings for containment of Cu-Mg-Si metallic phase change material

    DOE PAGES

    Withey, Elizabeth Ann; Kruizenga, Alan Michael; Andraka, Charles E.; ...

    2016-01-01

    In this study, the performance of Y2O3-stabilized ZrO2 (YSZ), Y2O3, and Al2O3 plasma sprayed coatings are investigated for their ability to prevent attack of Haynes 230 by a near-eutectic Cu-Mg-Si metallic phase change material (PCM) in a closed environment at 820 °C. Areas where coatings failed were identified with optical and scanning electron microscopy, while chemical interactions were clarified through elemental mapping using electron microprobe analysis. Despite its susceptibility to reduction by Mg, the Al2O3 coating performed well while the YSZ and Y2O3 coating showed clear areas of attack. These results are attributed to the evolution of gaseous Mg atmore » 820 °C leading to the formation of MgO and MgAl2O4.« less

  8. Characterization of the adherence of plasma-sprayed ZrO/sub 2/ coatings

    SciTech Connect

    Becher, P.F.; Rice, R.W.

    1980-01-01

    Analysis of the microstructure and adherence of ZrO/sub 2/ coatings revealed that the adherence decreased with increasing coating thickness and could be increased by incorporating MgO as a second phase as well as by including noncubic ZrO/sub 2/ in the cubic ZrO/sub 2/ coating. Residual stresses from the plasma spraying process limit adherence (hence the coating thickness dependence) but these can be relieved by plastic flow in the MgO phase during post-spray cooling. Some degree of strength/toughening is also derived by the presence of microcracks and/or from transformation associated with the presence of tetragonal ZrO/sub 2/.

  9. Effect of Zr on microstructure of metallic glass coatings prepared by gas tunnel type plasma spraying.

    PubMed

    Kobayashi, A; Kuroda, T; Kimura, H; Inoue, A

    2012-06-01

    Metallic glass is one of the most attractive advanced materials, and many researchers have conducted various developmental research works. Metallic glass is expected to be used as a functional material because of its excellent physical and chemical functions such as high strength and high corrosion resistance. However, the application for small size parts has been carried out only in some industrial fields. In order to widen the industrial application fields, a composite material is preferred for the cost performance. In the coating processes of metallic glass with the conventional deposition techniques, there is a difficulty to form thick coatings due to their low deposition rate. Thermal spraying method is one of the potential candidates to produce metallic glass composites. Metallic glass coatings can be applied to the longer parts and therefore the application field can be widened. The gas tunnel plasma spraying is one of the most important technologies for high quality ceramic coating and synthesizing functional materials. As the gas tunnel type plasma jet is superior to the properties of other conventional type plasma jets, this plasma has great possibilities for various applications in thermal processing. In this study, the gas tunnel type plasma spraying was used to form the metallic glass coatings on the stainless-steel substrate. The microstructure and surface morphology of the metallic glass coatings were examined using Fe-based metallic glass powder and Zr-based metallic glass powder as coating material. For the mechanical properties the Vickers hardness was measured on the cross section of both the coatings and the difference between the powders was compared.

  10. PLASMA SPRAYED Ni-Al COATINGS FOR SAFE ENDING HEAT EXCHANGER TUBES

    SciTech Connect

    ALLAN,M.L.; OTTERSON,D.; BERNDT,C.C.

    1998-11-01

    Brookhaven National Laboratory (BNL) has developed thermally conductive composite liners for corrosion and scale protection in heat exchanger tubes exposed to geothermal brine. The liners cannot withstand roller expansion to connect the tubes to the tubesheet. It is not possible to line the ends of the tubes with the same material after roller expansion due to the nature of the current liner application process. It was requested that BNL evaluate plasma sprayed Ni-Al coatings for safe ending heat exchanger tubes exposed to geothermal brine. The tubes of interest had an internal diameter of 0.875 inches. It is not typical to thermal spray small diameter components or use such small standoff distances. In this project a nozzle extension was developed by Zatorski Coating Company to spray the tube ends as well as flat coupons for testing. Four different Ni-Al coatings were investigated. One of these was a ductilized Ni-AIB material developed at Oak Ridge National Laboratory. The coatings were examined by optical and scanning electron microscopy. In addition, the coatings were analyzed by X-ray diffraction and subjected to corrosion, tensile adhesion, microhardness and field tests in a volcanic pool in New Zealand. It was determined that the Ni-Al coatings could be applied to a depth of two inches on the tube ends. When sprayed on flat coupons the coatings exhibited relatively high adhesion strength and microhardness. Polarization curves showed that the coating performance was variable. Measured corrosion potentials indicated that the Ni-Al coatings are active towards steel coated with thermally conductive polymers, thereby suggesting preferential corrosion. Corrosion also occurred on the coated coupons tested in the volcanic pool. This may have been exacerbated by the difficulty in applying a uniform coating to the coupon edges. The Ni-Al coatings applied to the tubes had significant porosity and did not provide adequate corrosion protection. This is associated with

  11. Investigations of Local Corrosion Behavior of Plasma-Sprayed FeCr Nanocomposite Coating by SECM

    NASA Astrophysics Data System (ADS)

    Shi, Xi; Shu, Mingyong; Zhong, Qingdong; Zhang, Junliang; Zhou, Qiongyu; Bui, Quoc Binh

    2016-02-01

    FeCr alloy coating can be sprayed on low-carbon steel to improve the corrosion resistance because of FeCr alloy's high anti-corrosion capacity. In this paper, Fe microparticles/Cr nanoparticles coating (NFC) and FeCr microparticles coating (MFC) were prepared by atmospheric plasma spraying and NFC was heat-treated under hydrogen atmosphere at 800 °C (HNFC). EDS mapping showed no penetration of Ni in MFC and NFC while penetration of Ni occurred in HNFC. X-ray diffraction results indicated the form of the NiCrFe (bcc) solid solution in HNFC. SECM testing in 3.5 (wt.%) NaCl revealed that the anti-corrosion capacity of NFC improved compared with MFC, while HNFC improved further.

  12. Pressure-Based Liquid Feed System for Suspension Plasma Spray Coatings

    NASA Astrophysics Data System (ADS)

    Cotler, Elliot M.; Chen, Dianying; Molz, Ronald J.

    2011-06-01

    Thermal spraying with liquid-based feedstocks demonstrated a potential to produce coatings with new and enhanced characteristics. A liquid delivery system prototype was developed and tested in this study. The feeder is based on the 5MPE platform and uses a pressure setup to optimally inject and atomize liquid feedstock into a plasma plume. A novel self-cleaning apparatus is incorporated into the system to greatly reduce problems associated with clogging and agglomeration of liquid suspensions. This approach also allows the liquid feedstock line to the gun to remain charged for quick on-off operation. Experiments on aqueous and ethanol-based suspensions of titania, alumina, and YSZ were performed through this liquid delivery system using a 9MB plasma gun. Coatings with ultrafine splat microstructures were obtained by plasma spraying of those suspensions. Phase composition and microstructure of the as-sprayed coatings were investigated.

  13. Effect of Solid Shield on Coating Properties in Atmospheric Plasma Spray Process

    NASA Astrophysics Data System (ADS)

    Liu, Ting; Zheng, Lili; Zhang, Hui

    2016-12-01

    This paper investigates the impact of shrouded shield structure on plasma spray processes and the selection of optimal shield structure. Response of plasma flame characteristics to solid shield structures is studied first, and experimental investigations are then performed for both atmospheric (APS) and shrouded (SPS) plasma spray processes. It is found that the usage of conical shield (divergence angle 5.5°) with 90 mm in length is effective to form a low-oxygen (<2%) and high-temperature (>3000 K) region in the plasma flame and this region can cover the majority area for particles passing by. The average particle temperature is higher in SPS than in APS with the given conditions, and such behavior is intensified as solid shield length increases. Using the SPS process, more disk-shaped splats are obtained, and the oxygen concentration in coating is significantly reduced. The degree of the oxidation in the coatings is further reduced as the length of the solid shield increases from 50 to 90 mm. Applying solid shield will lead to high flame temperature and low oxidation; however, the substrate overheating and velocity reduction may occur. For the cases studied, the optimal shield length is around 90 mm.

  14. Characterization of High-Velocity Single Particle Impacts on Plasma-Sprayed Ceramic Coatings

    NASA Astrophysics Data System (ADS)

    Kiilakoski, Jarkko; Lindroos, Matti; Apostol, Marian; Koivuluoto, Heli; Kuokkala, Veli-Tapani; Vuoristo, Petri

    2016-08-01

    High-velocity impact wear can have a significant effect on the lifetime of thermally sprayed coatings in multiple applications, e.g., in the process and paper industries. Plasma-sprayed oxide coatings, such as Cr2O3- and TiO2-based coatings, are often used in these industries in wear and corrosion applications. An experimental impact study was performed on thermally sprayed ceramic coatings using the High-Velocity Particle Impactor (HVPI) at oblique angles to investigate the damage, failure, and deformation of the coated structures. The impact site was characterized by profilometry, optical microscopy, and scanning electron microscopy (SEM). Furthermore, the connection between the microstructural details and impact behavior was studied in order to reveal the damage and failure characteristics at a more comprehensive level. Differences in the fracture behavior were found between the thermally sprayed Cr2O3 and TiO2 coatings, and a concept of critical impact energy is presented here. The superior cohesion of the TiO2 coating inhibited interlamellar cracking while the Cr2O3 coating suffered greater damage at high impact energies. The HVPI experiment has proven to be able to produce valuable information about the deformation behavior of coatings under high strain rates and could be utilized further in the development of wear-resistant coatings.

  15. Ablation Resistance of C/C Composites with Atmospheric Plasma-Sprayed W Coating

    NASA Astrophysics Data System (ADS)

    Zhou, Zhe; Wang, Yuan; Gong, Jieming; Ge, Yicheng; Peng, Ke; Ran, Liping; Yi, Maozhong

    2016-12-01

    To improve the ablation resistance of carbon/carbon (C/C) composites, tungsten (W) coating with thickness of 1.2 mm was applied by atmospheric plasma spraying. The antiablation property of the coated composites was evaluated by oxyacetylene flame ablation experiments. The phase composition of the coating was investigated by a combination of x-ray diffraction analysis and scanning electron microscopy with energy-dispersive x-ray spectroscopy analysis. The ablation resistance of the coated C/C substrates was compared with that of uncoated C/C composites and C/C-CuZr composites after ablation for 30 s. The properties of the coated C/C composites after ablation time of 10, 30, 60, 90, 120, and 180 s were further studied. The results indicated that the mass and linear ablation rates of the W-coated C/C composites were lower than those of uncoated C/C or C/C-CuZr composites after ablation for 30 s. The coating exhibited heat stability after 120 s of ablation, with mass loss and linear ablation rates of 7.39 × 10-3 g/s and 3.50 × 10-3 mm/s, respectively. However, the W coating became ineffective and failed after ablation for 180 s. Three ablation regions could be identified, in which the ablation mechanism of the coating changed from thermochemical to thermophysical erosion to mechanical scouring with increasing ablation time.

  16. Improvements in Microstructure and Wear Resistance of Plasma-Sprayed Fe-Based Amorphous Coating by Laser-Remelting

    NASA Astrophysics Data System (ADS)

    Jiang, Chaoping; Chen, Hong; Wang, Gui; Chen, Yongnan; Xing, Yazhe; Zhang, Chunhua; Dargusch, Matthew

    2017-03-01

    Amorphous coating technology is an attractive way of taking advantage of the superior properties of amorphous alloys for structural applications. However, the limited bonds between splats within the plasma-sprayed coatings result in a typically lamellar and porous coating structure. To overcome these limitations, the as-sprayed coating was treated by a laser-remelting process. The microstructure and phase composition of two coatings were analyzed using scanning electron microscopy with energy-dispersive spectroscopy, transmission electron microscopy, and x-ray diffraction. The wear resistance of the plasma-sprayed coating and laser-remelted coating was studied comparatively using a pin-on-disc wear test under dry friction conditions. It was revealed that the laser-remelted coating exhibited better wear resistance because of its defect-free and amorphous-nanocrystalline composited structure.

  17. Co-blasting of titanium surfaces with an abrasive and hydroxyapatite to produce bioactive coatings: substrate and coating characterisation.

    PubMed

    Dunne, Conor F; Twomey, Barry; O'Neill, Liam; Stanton, Kenneth T

    2014-01-01

    The aim of this work is to assess the influence of two blast media on the deposition of hydroxyapatite onto a titanium substrate using a novel ambient temperature coating technique named CoBlast. CoBlast was developed to address the problems with high temperature coating techniques. The blasting media used in this study were Al2O3 and a sintered apatite powder. The prepared and coated surfaces were compared to plasma sprayed hydroxyapatite on the same substrates using the same hydroxyapatite feedstock powder. X-ray diffraction analysis revealed the coating crystallinity was the same as the original hydroxyapatite feedstock powder for the CoBlast samples while evidence of amorphous hydroxyapatite phases and β-TCP was observed in the plasma sprayed samples. The blast media type significantly influences the adhesive strength of the coating, surface roughness of both the substrate and coating and the microstructure of the substrate. The coating adhesion increased for the CoBlasted samples from 50 MPa to 60 MPa for sintered apatite powder and alumina, respectively, while plasma spray samples were significantly lower (5 MPa) when tested using a modified pull-test. In conclusion, the choice of blast medium is shown to be a key parameter in the CoBlast process. This study indicates that sintered apatite powder is the most suitable candidate for use as a blast medium in the coating of medical devices.

  18. Creep of plasma-sprayed-ZrO2 thermal-barrier coatings

    NASA Technical Reports Server (NTRS)

    Firestone, R. F.; Logan, W. R.; Adams, J. W.; Bill, R. C., Jr.

    1982-01-01

    Specimens of plasma-sprayed-zirconia thermal-barrier coatings with three different porosities and different initial particle sizes were deformed in compression at initial loads of 6900, 13,800, and 24,100 kPa (1000, 2000, and 3500 psi) and temperatures of 1100, 1250, and 1400 C. The coatings were stabilized with lime, MgO, and two different concentrations of Y2O3. Creep began as soon as the load was applied and continued at a constantly decreasing rate until the load was removed. Temperature and stabilization had a pronounced effect on creep rate while the stress, particle size, and porosity had a lesser effect. Creep deformation was due to cracking and particle sliding.

  19. Post-treatment of Plasma-Sprayed Amorphous Ceramic Coatings by Spark Plasma Sintering

    NASA Astrophysics Data System (ADS)

    Chraska, T.; Pala, Z.; Mušálek, R.; Medřický, J.; Vilémová, M.

    2015-04-01

    Alumina-zirconia ceramic material has been plasma sprayed using a water-stabilized plasma torch to produce free standing coatings. The as-sprayed coatings have very low porosity and are mostly amorphous. The amorphous material crystallizes at temperatures above 900 °C. A spark plasma sintering apparatus has been used to heat the as-sprayed samples to temperatures above 900 °C to induce crystallization, while at the same time, a uniaxial pressure of 80 MPa has been applied to their surface. After such post-treatment, the ceramic samples are crystalline and have very low open porosity. The post-treated material exhibits high hardness and significantly increased flexural strength. The post-treated samples have a microstructure that is best described as nanocomposite with the very small crystallites embedded in an amorphous matrix.

  20. Synthesis, characterization and physical properties of Al-Cu-Fe quasicrystalline plasma sprayed coatings

    SciTech Connect

    Daniel, Sordelet

    1995-11-09

    Our lab has been working with plasma spraying of both high pressure gas atomized (HPGA) and cast and crushed quasicrystal powders. A major component of this research includes comparative studies of PAS coatings formed with starting powders prepared by both techniques. In addition, a thorough investigation of the effects of starting powder particle size on coating microstructure is included. During the course of the overall research, an interest developed in forming Al-Cu-Fe materials with finer grain sizes. Therefore, a brief study was performed to characterize the effect of adding boron to Al-Cu-Fe materials prepared by different techniques. In addition to characterizing the microstructural features of the above materials, oxidation and wear behavior was also examined.

  1. Mechanical Properties of Air Plasma Sprayed Environmental Barrier Coating (EBC) Materials

    NASA Technical Reports Server (NTRS)

    Richards, Bradley; Zhu, Dongming; Ghosn, Louis; Wadley, Haydn

    2015-01-01

    Development work in Environmental Barrier Coatings (EBCs) for Ceramic Matrix Composites (CMCs) has focused considerably on the identification of materials systems and coating architectures to meet application needs. The evolution of these systems has occurred so quickly that modeling efforts and requisite data for modeling lag considerably behind development. Materials property data exists for many systems in the bulk form, but the effects of deposition on the critical properties of strength and fracture behavior are not well studied. We have plasma sprayed bulk samples of baseline EBC materials (silicon, ytterbium disilicate) and tested the mechanical properties of these materials to elicit differences in strength and toughness. We have also endeavored to assess the mixed-mode fracture resistance, Gc, of silicon in a baseline EBC applied to SiCSiC CMC via four point bend test. These results are compared to previously determined properties of the comparable bulk material.

  2. Microstructure and Pitting Corrosion of Plasma-Sprayed Ni-Al Nanocomposite Coating

    NASA Astrophysics Data System (ADS)

    Shi, X.; Zhong, Q. D.

    2016-06-01

    Ni-Al nanoparticles coating (NAN) was manufactured via atmospheric plasma spraying (APS) and thermal treated under hydrogen atmosphere at 1300∘C (TNAN) remained 1 h, and NiAl microparticles coating (NAM) was manufactured as a reference. Nanoscale particles were observed in NAN by TEM, and these nanoscale particles disappeared in TNAN. Many pores and cracks were observed in NAM. Few pores and cracks were observed in NAN, and no pores and cracks were found in TNAN with SEM. A scanning electrochemical microscopy (SECM) testing in 3.5% (wt.) NaCl solution for 3 h revealed that NAM underwent several pitting corrosion, NAN pitting corrosion was relatively minor, and TNAN had no pitting corrosion.

  3. Failure of thick, low density air plasma sprayed thermal barrier coatings

    NASA Astrophysics Data System (ADS)

    Helminiak, Michael Aaron

    This research was directed at developing fundamental understandings of the variables that influence the performance of air plasma sprayed (APS) yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBC). Focus was placed on understanding how and why each variable influenced the performance of the TBC system along with how the individual variables interacted with one another. It includes research on the effect of surface roughness of NiCoCrAlY bond coats deposited by argon-shrouded plasma spraying, the interdiffusion behavior of bond coats coupled to commercial superalloys, and the microstructural and compositional control of APS topcoats to maximize the coating thicknesses that can be applied without spallation. The specimens used for this research were prepared by Praxair Surface Technologies and have been evaluated using cyclic oxidation and thermal shock tests. TBC performance was sensitive to bond coat roughness with the rougher bond coats having improved cyclic performance than the smoother bond coats. The explanation being the rough bond coat surface hindered the propagation of the delamination cracks. The failure mechanisms of the APS coatings were found to depend on a combination of the topcoat thickness, topcoat microstructure and the coefficient of thermal expansion (CTE) mismatch between the superalloy and topcoat. Thinner topcoats tended to fail at the topcoat/TGO interface due to bond coat oxidation whereas thicker topcoats failed within the topcoat due to the strain energy release rate of the thicker coating exceeding the fracture strength of the topcoat. Properties of free-standing high and conventional purity YSZ topcoats of both a lowdensity (LD) and dense-vertically fissure (DVF) microstructures were evaluated. The densification rate and phase evolution were sensitive to the YSZ purity and the starting microstructure. Increasing the impurity content resulted in enhanced sintering and phase decomposition rates, with the exception of the

  4. Microstructure and Thermal Properties of Atmospheric Plasma-Sprayed Yb2Si2O7 Coating

    NASA Astrophysics Data System (ADS)

    Zhong, Xin; Niu, Yaran; Huang, Liping; Li, Hong; Zheng, Xuebin; Ding, Chuanxian; Sun, Jinliang

    2017-01-01

    In the present work, Yb2Si2O7 powder was synthesized by solid-state reaction using Yb2O3 and SiO2 powders as starting materials. Atmospheric plasma spray technique was applied to fabricate Yb2Si2O7 coating. The phase composition and microstructure of the coating were characterized. The density, open porosity and Vickers hardness of the coating were investigated. Its thermal stability was evaluated by thermogravimetry and differential thermal analysis (TG-DTA). The thermal diffusivity and thermal conductivity of the coating were measured. The results showed that the as-sprayed coating was mainly composed of crystalline Yb2Si2O7 with amorphous phase. The coating had a dense structure containing defects, such as pores, interfaces and microcracks. The TG-DTA results showed that there was almost no mass change from room temperature to 1200 °C, while a sharp exothermic peak appeared at around 1038 °C in DTA curve, which indicated that the amorphous phase crystallized. The thermal conductivity of the coating decreased with rise in temperature up to 600 °C and then followed by an increase at higher temperatures. The minimum value of the thermal conductivity of the Yb2Si2O7 coating was about 0.68 W/(m K).

  5. The effect of thermal aging on the thermal conductivity of plasma sprayed and EB-PVD thermal barrier coatings

    SciTech Connect

    Dinwiddie, R.B.; Beecher, S.C.; Porter, W.D.; Nagaraj, B.A.

    1996-05-01

    Thermal barrier coatings (TBCs) applied to the hot gas components of turbine engines lead to enhanced fuel efficiency and component reliability. Understanding the mechanisms which control the thermal transport behavior of the TBCs is of primary importance. Electron beam-physical vapor deposition (EV-PVD) and air plasma spraying (APS) are the two most commonly used coating techniques. These techniques produce coatings with unique microstructures which control their performance and stability. The density of the APS coatings was controlled by varying the spray parameters. The low density APS yttria-partially stabilized zirconia (yttria-PSZ) coatings yielded a thermal conductivity that is lower than both the high density APS coatings and the EB-PVD coatings. The thermal aging of both fully and partially stabilized zirconia are compared. The thermal conductivity of the coatings permanently increases upon exposure to high temperatures. These increases are attributed to microstructural changes within the coatings. This increase in thermal conductivity can be modeled using a relationship which depends on both the temperature and time of exposure. Although the EB-PVD coatings are less susceptible to thermal aging effects, results suggest that they typically have a higher thermal conductivity than APS coatings before thermal aging. The increases in thermal conductivity due to thermal aging for plasma sprayed partially stabilized zirconia have been found to be less than for plasma sprayed fully stabilized zirconia coatings.

  6. Wide-temperature-spectrum self-lubricating coatings prepared by plasma spraying

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.

    1979-01-01

    Self-lubricating, multicomponent coatings, which lubricate over a wide range of operating conditions, are described. The coatings have been successfully applied by plasma-spraying mixed powders onto superalloy substrates. They have been evaluated in friction and wear experiments, and in sliding contact bearing tests. These coatings are wear resistant by virtue of their self-lubricating characteristics rather than because of extreme hardness; a further benefit is low friction. Experiments with simple pin on disk sliding specimens and oscillating plain cylindrical bearing tests were performed to evaluate the tribological properties of the coatings. It was shown that coatings of nichrome, glass and calcium fluoride are self-lubricating from about 500 to 900 C, but give high friction at the lower temperatures. The addition of silver to the coating composition improved the low temperature bearing properties and resulted in coatings which are self-lubricating from cryogenic temperatures to at least 870 C; they are therefore 'wide temperature spectrum,' self-lubricating compositions.

  7. Assessment of plasma sprayed coatings to modify surface friction for railroad applications

    NASA Astrophysics Data System (ADS)

    Davis, Heidi Lynn

    For the past hundred years, railroads have been an important means of transportation for passengers and freight. Over the years train traffic, speeds, and loads have increased steadily leading to a more severe wheel/rail environment that exceeds the design limits of the steels thus causing increased wear, decreased rail life, and higher maintenance costs. The cost of controlling friction and the resulting damage is an area of ever-increasing concern. One potential method of modifying friction is by changing the surface properties of the rail. The work reported herein was carried out as part of a larger effort to modify surface friction of rails. The original focus of this research was to use high velocity air plasma spraying to develop friction enhancing coatings for the rail surface. Using the methodology developed at the Oregon Graduate Institute, the plasma spray parameters were optimized and the coatings were tested on the Amsler machine under rolling/sliding wear conditions to determine viability prior to full scale testing. Stainless steel and composite 1080 steel were investigated as potential materials for increasing friction. Poor results with these coatings shifted the research focus to understanding the durability of the coatings and to failure analysis of initial 1080 steel full scale samples tested by the Facility for Accelerated Service Testing that had failed prematurely. After re-optimization of parameters and preparation methodologies further full scale samples (1080 steel/nylon) were tested and failure analysis was performed. Optical and scanning electron microscopy were used to evaluate the microstructure of coatings from the tested samples. The laboratory scale Amsler test did not appear to be a good indicator of the performance of the coating in full scale tests, because variations in microstructure were caused by differences in sample size, geometry and spraying methods when scaling up from a small Amsler roller to a large rail sample. The

  8. Sintering and Fracture Behavior of Plasma-sprayed Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Choi, Sung R.; Miller, Robert A.

    2004-01-01

    Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. There is a need to characterize the fundamental sintering and fracture behavior of the current ZrO2-(7 to 8)wt%Y2O3 coating, in order to fully take advantage of the coating capability. In addition, a thorough evaluation of the coating behavior and temperature limits will be useful for more accurately assessing the benefit gained from future advanced coating systems. In this study, the sintering behavior of plasma-sprayed ZrO2-8wt%Y2O3 coatings was systematically investigated as a function of temperature and time using a dilatometer in the temperature range of 1200-1500 C. The coating sintering kinetics obtained by dilatometry were compared with the coating thermal conductivity increase kinetics, determined by a steady-state laser heat-flux testing approach, under high temperature and thermal gradient sintering conditions. The mode I, mode II, and mixed mode I-mode II fracture behavior of as-processed and sintering-annealed coatings was determined in asymmetric flexure loading at ambient and elevated temperatures in order to evaluate the coating sintering effects on the fracture envelope of K(sub I) versus K(sub II). The coating thermal conductivity cyclic response associated with the interface delamination of the coating systems under simulated engine heat-flux conditions will be discussed in conjunction with the sintering and fracture testing results.

  9. Sintering and Creep Behavior of Plasma-Sprayed Zirconia and Hafnia Based Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Miller, Robert A.

    1998-01-01

    The sintering and creep of plasma-sprayed ceramic thermal barrier coatings under high temperature conditions are complex phenomena. Changes in thermomechanical and thermophysical properties and in the stress response of these coating systems as a result of the sintering and creep processes are detrimental to coating thermal fatigue resistance and performance. In this paper, the sintering characteristics of ZrO2-8wt%y2O3, ZrO2-25wt%CeO2-2.5wt%Y2O3, ZrO2-6w%NiO- 9wt%Y2O3, ZrO2-6wt%Sc2O3-2wt%y2O3 and HfO2-27wt%y2O3 coating materials were investigated using dilatometry. It was found that the HfO2-Y2O3 and baseline ZrO2-Y2O3 exhibited the best sintering resistance, while the NiO-doped ZrO2-Y2O3 showed the highest shrinkage strain rates during the tests. Higher shrinkage strain rates of the coating materials were also observed when the specimens were tested in Ar+5%H2 as compared to in air. This phenomenon was attributed to an enhanced metal cation interstitial diffusion mechanism under the reducing conditions. It is proposed that increased chemical stability of coating materials will improve the material sintering resistance.

  10. Preparation of SrZrO3 Thermal Barrier Coating by Solution Precursor Plasma Spray

    NASA Astrophysics Data System (ADS)

    Li, Xinhui; Ma, Wen; Wen, Jing; Bai, Yu; Sun, Li; Chen, Baodong; Dong, Hongying; Shuang, Yingchai

    2017-02-01

    The solution precursor plasma spray (SPPS) process is capable of depositing highly durable thermal barrier coatings (TBCs). In this study, an aqueous chemical precursor feedstock was injected into the plasma jet to deposit SrZrO3 thermal barrier coating on metal substrate. Taguchi design of experiments was employed to optimize the SPPS process. The thermal characteristics and phase evolution of the SrZrO3 precursor, as well as the influence of various spray parameters on the coating deposition rate, microhardness, microstructure, and phase stability, were investigated. The experimental results showed that, at given spray distance, feedstock flow rate, and atomization pressure, the optimized spray parameters were arc current of 600 A, argon flow rate of 40 L/min, and hydrogen flow rate of 10 L/min. The SrZrO3 coating prepared using the optimized spray parameters had single-pass thickness of 6.0 μm, porosity of 18%, and microhardness of 6.8 ± 0.1 GPa. Phase stability studies indicated that the as-sprayed SrZrO3 coating had good phase stability in the temperature range from room temperature to 1400 °C, gradually exhibiting a phase transition from t'-ZrO2 to m-ZrO2 in the SrZrO3 coating at 1450 °C with increasing time, while the SrZrO3 phase did not change.

  11. The low cycle fatigue behavior of a plasma-sprayed coating material

    NASA Technical Reports Server (NTRS)

    Gayda, J.; Gabb, T. P.; Miner, R. V., Jr.

    1986-01-01

    Single crystal nickel-base superalloys employed in turbine blade applications are often used with a plasma spray coating for oxidation and hot corrosion resistance. These coatings may also affect fatigue life of the superalloy substrate. As part of a large program to understand the fatigue behavior of coated single crystals, fully reversed, total strain controlled fatigue tests were run on a free standing NiCoCrAlY coating alloy, PWA 276, at 0.1 Hz. Fatigue tests were conducted at 650 C, where the NiCoCrAlY alloy has modest ductility, and at 1050 C, where it is extremely ductile, showing tensile elongation in excess of 100 percent. At the lower test temperature, deformation induced disordering softened the NiCoCrAlY alloy, while at the higher test temperature cyclic hardening was observed which was linked to gradual coarsening of the two phase microstructure. Fatigue life of the NiCoCrAlY alloy was significantly longer at the higher temperature. Further, the life of the NiCoCrAlY alloy exceeds that of coated, /001/-oriented PWA 1480 single crystals at 1050 C, but at 650 C the life of the coated crystal is greater than that of the NiCoCrAlY alloy on a total strain basis.

  12. Plasma sprayed manganese-cobalt spinel coatings: Process sensitivity on phase, electrical and protective performance

    NASA Astrophysics Data System (ADS)

    Han, Su Jung; Pala, Zdenek; Sampath, Sanjay

    2016-02-01

    Manganese cobalt spinel (Mn1.5Co1.5O4, MCO) coatings are prepared by the air plasma spray (APS) process to examine their efficacy in serving as protective coatings from Cr-poisoning of the cathode side in intermediate temperature-solid oxide fuel cells (IT-SOFCs). These complex oxides are susceptible to process induced stoichiometric and phase changes which affect their functional performance. To critically examine these effects, MCO coatings are produced with deliberate modifications to the spray process parameters to explore relationship among process conditions, microstructure and functional properties. The resultant interplay among particle thermal and kinetic energies are captured through process maps, which serve to characterize the parametric effects on properties. The results show significant changes to the chemistry and phase composition of the deposited material resulting from preferential evaporation of oxygen. Post deposition annealing recovers oxygen in the coatings and allows partial recovery of the spinel phase, which is confirmed through thermo-gravimetric analysis (TGA)/differential scanning calorimetry (DSC), X-ray Diffraction (XRD), and magnetic hysteresis measurements. In addition, coatings with high density after sintering show excellent electrical conductivity of 40 S cm-1 at 800 °C while simultaneously providing requisite protection characteristics against Cr-poisoning. This study provides a framework for optimal evaluation of MCO coatings in intermediate temperature SOFCs.

  13. The properties and fracture behavior of ion plasma sprayed TiN coating on stainless steel substrate

    NASA Astrophysics Data System (ADS)

    Orlova, Dina V.; Goncharenko, Igor M.; Danilov, Vladimir I.; Lobach, Maxim I.; Danilova, Lidiya V.; Shlyakhova, Galina V.

    2015-10-01

    The wear resistance and fracture behavior of ion plasma sprayed TiN coating were studied; the results are presented. The coating was applied to the stainless steel substrate using a vacuum arc method. The samples were tested by active loading. With varying coating thickness, its characteristics were found to change. Multiple cracking would occur in the deformed sample, with fragment borders aligned normal to the extension axis.

  14. Analysis of retrieved hydroxyapatite-coated hip prostheses

    NASA Astrophysics Data System (ADS)

    Gross, K. A.; Walsh, W.; Swarts, E.

    2004-06-01

    Hydroxyapatite (HAp) coatings are used extensively on orthopaedic devices to improve the adhesion of bone to the prosthesis. This approach increases the integrity and longevity of the implanted prosthesis. Four HAp-coated hip components recovered from patients during revision surgery were investigated for bone attachment and coating modification after storage in ethanol or formaldehyde. Orthopedic components displayed preferable bone attachment on microtextured areas and little bone on smoother areas. The coating microstructure differed between three coatings that remained on the prosthesis surface, ranging from completely crystalline coatings made by vacuum plasma spraying to less crystalline coatings manufactured by air plasma spraying. Coating failure for the lower crystallinity coatings was observed by a crack at the interface that was possibly caused by the dissolution of an amorphous phase. While higher crystallinity coatings degraded by coating delamination, the lower crystallinity coating produced loose particulate on the outer coating surface. Coating morphology as observed by scanning electron microscopy (SEM) displayed lamellae fracture, chemical dissolution, osteoclastic resorption, and precipitation in agreement with previously identified in-vitro events. The coating longevity appeared to be extended in those areas subject to lower levels of stress and more bone coverage.

  15. Studies on the Sliding Wear Performance of Plasma Spray Ni-20Cr and Ni3Al Coatings

    NASA Astrophysics Data System (ADS)

    Kaur, Maninder; Singh, Harpreet; Singh, Balraj; Singh, Bhupinder

    2010-01-01

    Two metallic powders namely Ni-20Cr and Ni3Al were coated on AISI 309 SS steel by shrouded plasma spray process. The wear behavior of the bare, Ni-20Cr and Ni3Al-coated AISI 309 SS steel was investigated according to ASTM Standard G99-03 on a Pin-on-Disc Wear Test Rig. The wear tests were carried out at normal loads of 30 and 50 N with a sliding velocity of 1 m/s. Cumulative wear rate and coefficient of friction (μ) were calculated for all the cases. The worn-out surfaces were then examined by scanning electron microscopy analysis. Both the as-sprayed coatings exhibited typical splat morphology. The XRD analysis indicated the formation of Ni phase for the Ni-20Cr coating and Ni3Al phase for the Ni3Al coating. It has been concluded that the plasma-sprayed Ni-20Cr and Ni3Al coatings can be useful to reduce the wear rate of AISI 309 SS steel. The coatings were found to be adherent to the substrate steel during the wear tests. The plasma-sprayed Ni3Al coating has been recommended as a better choice to reduce the wear of AISI 309 SS steel, in comparison with the Ni-20Cr coating.

  16. An Assessment of the Residual Stresses in Low Pressure Plasma Sprayed Coatings on an Advanced Copper Alloy

    NASA Technical Reports Server (NTRS)

    Raj, S. V.; Ghosn, L. J.; Agarwal, A.; Lachtrupp, T. P.

    2002-01-01

    Modeling studies were conducted on low pressure plasma sprayed (LPPS) NiAl top coat applied to an advanced Cu-8(at.%)Cr-4%Nb alloy (GRCop-84) substrate using Ni as a bond coat. A thermal analysis suggested that the NiAl and Ni top and bond coats, respectively, would provide adequate thermal protection to the GRCop-84 substrate in a rocket engine operating under high heat flux conditions. Residual stress measurements were conducted at different depths from the free surface on coated and uncoated GRCop-84 specimens by x-ray diffraction. These data are compared with theoretically estimated values assessed by a finite element analysis simulating the development of these stresses as the coated substrate cools down from the plasma spraying temperature to room temperature.

  17. Very low pressure plasma sprayed yttria-stabilized zirconia coating using a low-energy plasma gun

    NASA Astrophysics Data System (ADS)

    Zhu, Lin; Zhang, Nannan; Bolot, Rodolphe; Planche, Marie-Pierre; Liao, Hanlin; Coddet, Christian

    2011-12-01

    In the present study, a more economical low-energy plasma source was used to perform a very low pressure plasma-spray (VLPPS) process. The plasma-jet properties were analyzed by means of optical emission spectroscopy (OES). Moreover, yttria-stabilized zirconia coating (YSZ) was elaborated by a F100 low-power plasma gun under working pressure of 1 mbar, and the substrate specimens were partially shadowed by a baffle-plate during plasma spraying for obtaining different coating microstructures. Based on the SEM observation, a column-like grain coating was deposited by pure vapor deposition at the shadowed region, whereas, in the unshadowed region, the coating exhibited a binary microstructure which was formed by a mixed deposition of melted particles and evaporated particles. The mechanical properties of the coating were also well under investigation.

  18. Vapors and Droplets Mixture Deposition of Metallic Coatings by Very Low Pressure Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Vautherin, B.; Planche, M.-P.; Bolot, R.; Quet, A.; Bianchi, L.; Montavon, G.

    2014-04-01

    In recent years, the very low pressure plasma-spraying (VLPPS) process has been intensely developed and implemented to manufacture thin, dense and finely structured ceramic coatings for various applications, such as Y2O3 for diffusion barriers, among other examples. This paper aims at presenting developments carried out on metallic coatings. Aluminum was chosen as a demonstrative material due to its "moderate" vaporization enthalpy (i.e., 38.23 KJ cm-3) compared to the one of copper (i.e., 55.33 KJ cm-3), cobalt (i.e., 75.03 KJ cm-3), or even tantalum (i.e., 87.18 KJ cm-3). The objective of this work is primarily to better understand the behavior of a solid precursor injected into the plasma jet leading to the formation of vapors and to better control the factors affecting the coating structure. Nearly dense aluminum coatings were successfully deposited by VLPPS at 100 Pa with an intermediate power plasma torch (i.e., Sulzer Metco F4 type gun with maximum power of 45 kW). Optical emission spectroscopy (OES) was implemented to study and analyze the vapor behavior into the plasma jet. Simplified CFD modeling allowed better understanding of some of the thermo-physical mechanisms. The effect of powder-size distribution, substrate temperature and spray distance were studied. The phase composition and microstructural features of the coatings were characterized by XRD and SEM. Moreover, Vickers microhardness measurements were implemented.

  19. Plasma Sprayed Bondable Stainless Surface (BOSS) Coatings for Corrosion Protection and Adhesion Treatments

    NASA Technical Reports Server (NTRS)

    Davis, G. D.; Groff, G. B.; Rooney, M.; Cooke, A. V.; Boothe, R.

    1995-01-01

    Plasma-sprayed Bondable Stainless Surface (BOSS) coatings are being developed under the Solid Propulsion Integrity Program's (SPIP) Bondlines Package. These coatings are designed as a steel case preparation treatment prior to insulation lay-up. Other uses include the exterior of steel cases and bonding surfaces of nozzle components. They provide excellent bondability - rubber insulation and epoxy bonds fail cohesively within the polymer - for both fresh surfaces and surfaces having undergone natural and accelerated environmental aging. They have passed the MSFC requirements for protection of inland and sea coast environment. Because BOSS coatings are inherently corrosion resistant, they do not require preservation by greases or oils. The reduction/elimination of greases and oils, known bondline degraders, can increase SRM reliability, decrease costs by reducing the number of process steps, and decrease environmental pollution by reducing the amount of methyl chloroform used for degreasing and thus reduce release of the ozone-depleting chemical in accordance with the Clean Air Act and the Montreal Protocol. The coatings can potential extend the life of RSRM case segments and nozzle components by eliminating erosion due to multiple grit blasting during each use cycle and corrosion damage during marine recovery. Concurrent work for the Air Force show that other BOSS coatings give excellent bondline strength and durability for high-performance structures of aluminum and titanium.

  20. Plasma Sprayed Ni-Al Coatings for Safe Ending Heat Exchanger Tubes

    SciTech Connect

    Allen, M.L.; Berndt, C.C.; Otterson, D.

    1998-11-01

    Brookhaven National Laboratory (BNL) has developed thermally conductive composite liners for corrosion and scale protection in heat exchanger tubes exposed to geothermal brine. The liners cannot withstand roller expansion to connect the tubes to the tubesheet. It is not possible to line the ends of the tubes with the same material after roller expansion due to the nature of the current liner application process. It was requested that BNL evaluate plasma sprayed Ni-Al coatings for safe ending heat exchanger tubes exposed to geothermal brine. The tubes of interest had an internal diameter of 0.875 inches. It is not typical to thermal spray small diameter components or use such small standoff distances. In this project a nozzle extension was developed by Zatorski Coating Company to spray the tube ends as well as flat coupons for testing. Four different Ni-Al coatings were investigated. One of these was a ductilized Ni-AlB material developed at Oak Ridge National Laboratory. The coatings were examined by optical and scanning electron microscopy. In addition, the coatings were analyzed by X-ray diffraction and subjected to corrosion, tensile adhesion, microhardness and field tests in a volcanic pool in New Zealand.

  1. Early apatite deposition and osteoblast growth on plasma-sprayed dicalcium silicate coating.

    PubMed

    Liu, Xuanyong; Xie, Youtao; Ding, Chuanxian; Chu, Paul K

    2005-09-01

    Dicalcium silicate coating was deposited onto a Ti-6Al-4V substrate using plasma-spraying technology. The coating was immersed in simulated body fluid (SBF) for 1, 3, 6, 12, 24, and 48 h to investigate early apatite formation on the coating. Osteoblasts were also seeded onto the surface of the dicalcium silicate coating to evaluate its biocompatibility. Cold field-emission scanning electron microscopy and energy-dispersive X-ray spectrometry were used to evaluate the morphologies and determine the chemical composition of the coatings. The surface structural changes caused by immersion in SBF were analyzed using thin-film X-ray diffraction. After the dicalcium silicate coating was soaked in SBF solution 1-6 h, two types of particles containing calcium and phosphorus were formed on the surface. One type consisted of relatively larger particles (P1) precipitated on the surface of the coating from the precursor cluster formed in the SBF solution. The second type was composed of particles (P2) nucleated on the surface of the coating. With increasing immersion time, the particles coalesced to form a surface Ca-P layer. The Ca-P layer was composed of amorphous calcium phosphate that was not transformed to crystalline apatite until the immersion time in SBF exceeded 24 h. The formation mechanism of the Ca-P layer and apatite on the surface of the coating is believed to be involved in the formation of the Si 3-ring active surface site with negative charge. The cell-seeding test revealed that osteoblasts grew and proliferated very well on the surface of the dicalcium silicate coating.

  2. Mechanical Properties of Yttria- and Ceria-Stabilized Zirconia Coatings Obtained by Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Łatka, Leszek; Cattini, Andrea; Chicot, Didier; Pawłowski, Lech; Kozerski, Stefan; Petit, Fabrice; Denoirjean, Alain

    2013-03-01

    Plasma generated by the SG-100 torch was applied to spray suspension formulated with the use of ZrO2 + 8 wt.% Y2O3 (8YSZ) and ZrO2 + 24 wt.% CeO2 + 2.5 wt.% Y2O3 (24CeYSZ) as solid phases. The suspensions were formulated with the use of 20 wt.% solid phase, 40 wt.% water, and 40 wt.% ethanol. The plasma spray parameters were optimized by keeping constant: (a) the electric power of 40 kW and (b) the working gas compositions of 45 slpm for Ar and 5 slpm for H2. On the other hand, the spray distance was varied from 40 to 60 mm and the torch linear speed was varied from 300 to 500 mm/s. The coatings were sprayed onto stainless steel substrates, and their thicknesses were in the range from 70 to 110 μm. The coating microstructures were analyzed with a scanning electron microscope. Mechanical properties were tested with the different methods including the indentation and scratch tests. The indentation test, carried out with various loads ranging from 100 to 10,000 mN, enabled to determine elastic modulus and Martens microhardness. Young's modulus of the coatings was in the range of 71-107 GPa for 8YSZ and 68-130 GPa for 24CeYSZ coatings. The scratch test enabled the authors to find the scratch macrohardness.

  3. High Temperature Multilayer Environmental Barrier Coatings Deposited Via Plasma Spray-Physical Vapor Deposition

    NASA Technical Reports Server (NTRS)

    Harder, Bryan James; Zhu, Dongming; Schmitt, Michael P.; Wolfe, Douglas E.

    2014-01-01

    Si-based ceramic matrix composites (CMCs) require environmental barrier coatings (EBCs) in combustion environments to avoid rapid material loss. Candidate EBC materials have use temperatures only marginally above current technology, but the addition of a columnar oxide topcoat can substantially increase the durability. Plasma Spray-Physical Vapor Deposition (PS-PVD) allows application of these multilayer EBCs in a single process. The PS-PVD technique is a unique method that combines conventional thermal spray and vapor phase methods, allowing for tailoring of thin, dense layers or columnar microstructures by varying deposition conditions. Multilayer coatings were deposited on CMC specimens and assessed for durability under high heat flux and load. Coated samples with surface temperatures ranging from 2400-2700F and 10 ksi loads using the high heat flux laser rigs at NASA Glenn. Coating morphology was characterized in the as-sprayed condition and after thermomechanical loading using electron microscopy and the phase structure was tracked using X-ray diffraction.

  4. Plasma sprayed coatings for containment of Cu-Mg-Si metallic phase change material

    SciTech Connect

    Withey, Elizabeth Ann; Kruizenga, Alan Michael; Andraka, Charles E.; Gibbs, Paul J.

    2016-01-01

    In this study, the performance of Y2O3-stabilized ZrO2 (YSZ), Y2O3, and Al2O3 plasma sprayed coatings are investigated for their ability to prevent attack of Haynes 230 by a near-eutectic Cu-Mg-Si metallic phase change material (PCM) in a closed environment at 820 °C. Areas where coatings failed were identified with optical and scanning electron microscopy, while chemical interactions were clarified through elemental mapping using electron microprobe analysis. Despite its susceptibility to reduction by Mg, the Al2O3 coating performed well while the YSZ and Y2O3 coating showed clear areas of attack. These results are attributed to the evolution of gaseous Mg at 820 °C leading to the formation of MgO and MgAl2O4.

  5. High-temperature thermo-mechanical behavior of functionally graded materials produced by plasma sprayed coating: Experimental and modeling results

    NASA Astrophysics Data System (ADS)

    Choi, Kang Hyun; Kim, Hyun-Su; Park, Chang Hyun; Kim, Gon-Ho; Baik, Kyoung Ho; Lee, Sung Ho; Kim, Taehyung; Kim, Hyoung Seop

    2016-09-01

    Thermal barrier coatings are widely used in aerospace industries to protect exterior surfaces from harsh environments. In this study, functionally graded materials (FGMs) were investigated with the aim to optimize their high temperature resistance and strength characteristics. NiCrAlY bond coats were deposited on Inconel-617 superalloy substrate specimens by the low vacuum plasma spraying technique. Functionally graded Ni-yttria-stabilized zirconia (YSZ) coatings with gradually varying amounts of YSZ (20%-100%) were fabricated from composite powders by vacuum plasma spraying. Heat shield performance tests were conducted using a high- temperature plasma torch. The temperature distributions were measured using thermocouples at the interfaces of the FGM layers during the tests. A model for predicting the temperature at the bond coating-substrate interface was established. The temperature distributions simulated using the finite element method agreed well with the experimental results.

  6. Anisotropic Mechanical Properties of Plasma-Sprayed Thermal Barrier Coatings at High Temperature Determined by Ultrasonic Method

    NASA Astrophysics Data System (ADS)

    Wei, Qin; Zhu, Jianguo; Chen, Wei

    2016-02-01

    The mechanical properties of plasma-sprayed thermal barrier coatings (TBC) are of great scientific and technological significance for the design and fabrication of TBC systems. The ultrasonic method combined with a sing-around method for mechanical properties measurement of TBC is deduced and the elastic modulus can be determined in the spray, or longitudinal, direction, and the transverse direction. Tested specimens of plasma-sprayed TBC are detached from the substrate and treated with thermal exposure at 1400 °C. The elastic moduli along the longitudinal and transverse directions of the TBCs are measured by different types of ultrasonic waves combined with a sing-around method, while the Poisson's ratio is also obtained simultaneously. The experimental results indicate that the magnitude of longitudinal elastic modulus is larger than that of the transverse one, and thus the plasma-sprayed TBC has an anisotropic mechanical property. Moreover, the elastic moduli along both longitudinal and transverse directions change with high-temperature exposure time, which consists of a rapid increasing stage followed by a slow decreasing stage. In addition, the magnitude of Poisson's ratio increases slightly from 0.05 to 0.2 with the high-temperature exposure time. Generally, the microstructures in the plasma-sprayed coatings and their evolution in a high-temperature environment are the main causes of the varying anisotropic mechanical properties.

  7. Method and Process Development of Advanced Atmospheric Plasma Spraying for Thermal Barrier Coatings

    NASA Astrophysics Data System (ADS)

    Mihm, Sebastian; Duda, Thomas; Gruner, Heiko; Thomas, Georg; Dzur, Birger

    2012-06-01

    Over the last few years, global economic growth has triggered a dramatic increase in the demand for resources, resulting in steady rise in prices for energy and raw materials. In the gas turbine manufacturing sector, process optimizations of cost-intensive production steps involve a heightened potential of savings and form the basis for securing future competitive advantages in the market. In this context, the atmospheric plasma spraying (APS) process for thermal barrier coatings (TBC) has been optimized. A constraint for the optimization of the APS coating process is the use of the existing coating equipment. Furthermore, the current coating quality and characteristics must not change so as to avoid new qualification and testing. Using experience in APS and empirically gained data, the process optimization plan included the variation of e.g. the plasma gas composition and flow-rate, the electrical power, the arrangement and angle of the powder injectors in relation to the plasma jet, the grain size distribution of the spray powder and the plasma torch movement procedures such as spray distance, offset and iteration. In particular, plasma properties (enthalpy, velocity and temperature), powder injection conditions (injection point, injection speed, grain size and distribution) and the coating lamination (coating pattern and spraying distance) are examined. The optimized process and resulting coating were compared to the current situation using several diagnostic methods. The improved process significantly reduces costs and achieves the requirement of comparable coating quality. Furthermore, a contribution was made towards better comprehension of the APS of ceramics and the definition of a better method for future process developments.

  8. Improvement of Coating Properties in Three-Cathode Atmospheric Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Bobzin, K.; Kopp, N.; Warda, T.; Petković, I.; Zimmermann, S.; Hartz-Behrend, K.; Landes, K.; Forster, G.; Kirner, S.; Marqués, J.-L.; Schein, J.; Prehm, J.; Möhwald, K.; Bach, Fr.-W.

    2013-04-01

    The main aim of this study is to improve the coating properties of three-cathode atmospheric plasma-sprayed coatings with respect to porosity and residual stresses. This was done by means of numerical simulation coupled with advanced diagnostic methods. A numerical model for the triple injection of alumina feedstock, as well as acceleration and heating of the powder particles in the characteristic threefold symmetrical plasma jet cross section produced by a three-cathode-plasma torch, was developed. The modeling results for the standard injector's position "0" were calculated and experimentally verified by laser Doppler anemometry. Based on the criteria defined for the concentrated feedstock transport and homogeneous thermal treatment of powder particles in the plasma jet, the optimal injection position was found. In the next step, a previously developed, coupled CFD-FEM-simulation model was used for simulations of the coating build-up, describing flattening, solidification, and deformation due to shrinkage for alumina particles on a rough substrate surface.

  9. Highly Segmented Thermal Barrier Coatings Deposited by Suspension Plasma Spray: Effects of Spray Process on Microstructure

    NASA Astrophysics Data System (ADS)

    Chen, Xiaolong; Honda, Hiroshi; Kuroda, Seiji; Araki, Hiroshi; Murakami, Hideyuki; Watanabe, Makoto; Sakka, Yoshio

    2016-12-01

    Effects of the ceramic powder size used for suspension as well as several processing parameters in suspension plasma spraying of YSZ were investigated experimentally, aiming to fabricate highly segmented microstructures for thermal barrier coating (TBC) applications. Particle image velocimetry (PIV) was used to observe the atomization process and the velocity distribution of atomized droplets and ceramic particles travelling toward the substrates. The tested parameters included the secondary plasma gas (He versus H2), suspension injection flow rate, and substrate surface roughness. Results indicated that a plasma jet with a relatively higher content of He or H2 as the secondary plasma gas was critical to produce highly segmented YSZ TBCs with a crack density up to 12 cracks/mm. The optimized suspension flow rate played an important role to realize coatings with a reduced porosity level and improved adhesion. An increased powder size and higher operation power level were beneficial for the formation of highly segmented coatings onto substrates with a wider range of surface roughness.

  10. Quasistatic vs. Dynamic Modulus Measurements Of Plasma-Sprayed Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Eldridge, J. I.; Morscher, G. N.; Choi, S. R.

    2002-01-01

    Plasma-sprayed 8wt% yttria-stabilized zirconia (8YSZ) thermal barrier coatings (TBCs) have been demonstrated to exhibit nonlinear hysteretic elastic behavior by quasistatic cyclic compression and cylindrical punch indentation measurements. In particular, the instantaneous (tangential) elastic modulus increases with applied stress and exhibits significant hysteresis during cycling. Sound velocity (dynamic) measurements also show an increase in TBC modulus with applied compressive stress, but in contrast show no significant hysteresis for the modulus during cycling. The nonlinear elastic behavior of the TBCs evidenced by these tests is attributed to coating compaction and internal sliding. The differences between the quasistatic and dynamic measurements are explained by the relative absence of the effect of internal sliding in the dynamic modulus measurements. By incorporating short load reversals into the larger loading cycle and measuring the instantaneous modulus at the start of each load reversal, the effects of internal sliding can be substantially reduced in the quasistatic measurements, and the resulting modulus values show good agreement with the modulus values determined by dynamic sound velocity measurements.

  11. Characteristics of yttrium fluoride and yttrium oxide coatings for plasma process equipment prepared by atmospheric plasma spraying

    NASA Astrophysics Data System (ADS)

    Lin, Tzu-Ken; Wuu, Dong-Sing; Huang, Shih-Yung; Wang, Wei-Kai

    2016-12-01

    In this study, yttrium fluoride (YF3) and yttrium oxide (Y2O3) coatings were prepared by an atmospheric plasma spraying technique and characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), and X-ray photoelectron spectroscopy (XPS). YF3 powders were sprayed at various plasma spraying powers of 9, 15, and 21 kW. The XRD result indicates that the YF3 coating shows preferred orientations and was well crystallized. The XPS results revealed a strong Y-F bond on the YF3 coating surface. A porosity value analysis showed that the porosity of the YF3 coating was lower than that of the Y2O3 coating. Moreover, the dielectric strength of the YF3 coating (22.65 kV/mm) was higher than that of the Y2O3 coating (14.42 kV/mm). This confirms that the YF3 coating exhibits a breakdown voltage of 4.97 kV, which is more than 1.5 times higher than that observed for the Y2O3 coating (3.29 kV). These results indicate that the YF3 coating has better mechanical and dielectric properties than the Y2O3 coating, indicating that the YF3 coating is a very attractive novel antiplasma and corrosion-resistant material.

  12. [Hydroxyapatite bioactive coating on carbon/carbon composites].

    PubMed

    Sui, Jinling; Li, Musen; Lü, Yupeng; Bai, Yunqiang

    2005-04-01

    A simple plasma spraying method was employed in coating hydroxyapaptite (HA) on to carbon/carbon composites (C/C composites). The morphology of the coating was examined under scanning electron microscope (SEM). The phase constitutions of the HA coating were determined by X-ray diffractometer (XRD). The shear strength of the HA coating-C/C composite substrates was detected. A hydroxyapatite coating with rough surface was observed. A considerable amount of amorphous phase appeared as a result from the coating process, which could be transformed into the morphous phase crystalline HA after subsequent heat treatment. The shear strength between the HA coating and C/C composite substrates was 7.15 MPa.

  13. Effect of Particle Size on the Micro-cracking of Plasma-Sprayed YSZ Coatings During Thermal Cycle Testing

    NASA Astrophysics Data System (ADS)

    Huang, Jibo; Wang, Weize; Yu, Jingye; Wu, Liangmin; Feng, Zhengqu

    2017-03-01

    The failure of plasma-sprayed thermal barrier coatings (TBCs) during service or thermal cycle testing usually results from internal cracking in the top coat, erosion and CMAS (calcium-magnesium-alumina-silicate)-induced damage, etc. The microstructure of ceramic coatings affects their durability and other properties of TBCs. In the present study, yttria-stabilized zirconia (YSZ) coatings were deposited by atmospheric plasma spraying (APS) using feedstocks with different particle sizes. In addition, the effect of particle size on damage evolution in the top coat was investigated. It is found that the coatings deposited using coarse particles show the higher thermal cycle life. Crack length grew with increasing numbers of thermal cycles. The faster crack growth rate can be found for the coatings deposited from fine particles. The porosity of the coating made from the coarse powder is larger than the porosity of the coating made from fine powder both in the as-sprayed condition and after thermal cycling. The changes in crack growth rate and the porosity are related to the effect of sintering and stress evolution in coatings during the thermal cyclic tests.

  14. Effect of Sintering on Mechanical and Physical Properties of Plasma-Sprayed Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Choi, Sung R.; Zhu, Dong-Ming; Miller, Robert A.

    2004-01-01

    The effect of sintering on mechanical and physical properties of free-standing plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings (TBCs) was determined by annealing them at 1316 C in air. Mechanical and physical properties of the TBCs, including strength, modes I and II fracture toughness, elastic modulus, Poisson s response, density, microhardness, fractography, and phase stability, were determined at ambient temperature as a function of annealing time ranging from 0 to 500 h. All mechanical and physical properties, except for the amount of monoclinic phase, increased significantly in 5 to 100 h and then reached a plateau above 100 h. Annealing resulted in healing of microcracks and pores and in grain growth, accompanying densification of the TBC s body due to the sintering effect. However, an inevitable adverse effect also occurred such that the desired lower thermal conductivity and good expansivity, which makes the TBCs unique in thermal barrier applications, were degraded upon annealing. A model was proposed to assess and quantify all the property variables in response to annealing in a normalized scheme. Directionality of as-sprayed TBCs appeared to have an insignificant effect on their properties, as determined via fracture toughness, microhardness, and elastic modulus measurements.

  15. Fireside Corrosion Behavior of HVOF and Plasma-Sprayed Coatings in Advanced Coal/Biomass Co-Fired Power Plants

    NASA Astrophysics Data System (ADS)

    Hussain, T.; Dudziak, T.; Simms, N. J.; Nicholls, J. R.

    2013-06-01

    This article presents a systematic evaluation of coatings for advanced fossil fuel plants and addresses fireside corrosion in coal/biomass-derived flue gases. A selection of four candidate coatings: alloy 625, NiCr, FeCrAl and NiCrAlY were deposited onto superheaters/reheaters alloy (T91) using high-velocity oxy-fuel (HVOF) and plasma spraying. A series of laboratory-based fireside corrosion exposures were carried out on these coated samples in furnaces under controlled atmosphere for 1000 h at 650 °C. The tests were carried out using the "deposit-recoat" test method to simulate the environment that was anticipated from air-firing 20 wt.% cereal co-product mixed with a UK coal. The exposures were carried out using a deposit containing Na2SO4, K2SO4, and Fe2O3 to produce alkali-iron tri-sulfates, which had been identified as the principal cause of fireside corrosion on superheaters/reheaters in pulverized coal-fired power plants. The exposed samples were examined in an ESEM with EDX analysis to characterize the damage. Pre- and post-exposure dimensional metrologies were used to quantify the metal damage in terms of metal loss distributions. The thermally sprayed coatings suffered significant corrosion attack from a combination of aggressive combustion gases and deposit mixtures. In this study, all the four plasma-sprayed coatings studied performed better than the HVOF-sprayed coatings because of a lower level of porosity. NiCr was found to be the best performing coating material with a median metal loss of ~87 μm (HVOF sprayed) and ~13 μm (plasma sprayed). In general, the median metal damage for coatings had the following ranking (in the descending order: most to the least damage): NiCrAlY > alloy 625 > FeCrAl > NiCr.

  16. Thermal barrier coating life and isothermal oxidation of low-pressure plasma-sprayed bond coat alloys

    NASA Technical Reports Server (NTRS)

    Brindley, W. J.; Miller, R. A.

    1990-01-01

    The paper investigates the isothermal oxidation kinetics of Ni-35Cr-6Al-0.95Y, Ni-18Cr-12Al-0.3Y, and Ni-16Cr-6Al-0.3Y low-pressure plasma-sprayed bond coat alloys and examines the effect of these alloys on the thermal barrier coating (TBC) cyclic life. TBC life was examined by cycling substrates coated with the different bond coats and a ZrO2-7 wt pct Y2O3 TBC in an air-rich burner rig flame between 1150 C and room temperature. The oxidation kinetics of the three bond coat alloys was examined by isothermal oxidation of monolithic NJiCrAlY coupons at 1083 C. The Ni-35Cr-6Al-0.95Y alloy exhibits comparatively high isothermal oxidation weight gains and provides the longest TBC life, whereas the Ni-16Cr-6Al-0.3Y alloy had the lowest weight gains and provided the shortest TBC life. The results show that, although bond coat oxidation is known to have a strong detrimental effect on TBC life, it is not the only bond coat factor that determines TBC life.

  17. Characterization of Nanostructured NbSi2 Intermetallic Coatings Obtained by Plasma Spraying of Mechanically Alloyed Powders

    NASA Astrophysics Data System (ADS)

    Yazdani, Zohreh; Karimzadeh, Fathallah; Abbasi, Mohammad-Hasan

    2015-08-01

    Nanostructured NbSi2 powders plasma sprayed on to Ti-6Al-4V substrates were characterized in this research. After preparation of the nanostructured NbSi2 powders by mechanical alloying of an Nb-Si powder mixture, agglomeration was performed to obtain a particle size suitable for spraying. The agglomerated powders were then sprayed by atmospheric plasma spraying. Structural transformation of the powders and morphological and mechanical changes of the coatings were examined by use of x-ray diffraction analysis, scanning electron microscopy, energy dispersive spectroscopy, and microhardness testing. During milling, NbSi2 intermetallic with a grain size of approximately 15 nm was gradually formed. After plasma spraying, a coating of hardness 550 ± 8 HV with a uniform nanocrystalline structure, low oxide content, low porosity, and a good adhesion to the substrate was obtained. No phase change occurred after spraying and the NbSi2 compound remained nanostructured with a grain size of approximately 82 nm.

  18. Bulge Testing and Interface Fracture Characterization of Plasma-Sprayed and HIP Bonded Zr Coatings on U-Mo

    NASA Astrophysics Data System (ADS)

    Hollis, K.; Liu, C.; Leckie, R.; Lovato, M.

    2015-01-01

    Bulge testing using a pressurized fluid to fracture the interface between bonded material layers along with three-dimensional digital image correlation to measure the sample distortion caused by pressurized fluid was applied to plasma-sprayed coatings. The initiation fracture toughness associated with the bonded materials was measured during the testing. The bulge testing of the uranium-molybdenum alloy plasma sprayed with zirconium and clad in aluminum is presented. The initiation fracture toughness was observed to increase with the increasing cathodic arc-cleaning current and the use of alternating polarity transferred arc current. This dependence was linked to the interface composition of oxide and mixed metal phases along with the interface temperature during spray deposition.

  19. Friction and wear of plasma-sprayed coatings containing cobalt alloys from 25 deg to 650 deg in air

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.; Jacobson, T. P.

    1979-01-01

    Four different compositions of self-lubricating, plasma-sprayed, composite coatings with calcium fluoride dispersed throughout cobalt alloy-silver matrices were evaluated on a friction and wear apparatus. In addition, coatings of the cobalt alloys alone and one coating with a nickel alloy-silver matrix were evaluated for comparison. The wear specimens consisted of two, diametrically opposed, flat rub shoes sliding on the coated, cylindrical surface of a rotating disk. Two of the cobalt composite coatings gave a friction coefficient of about 0.25 and low wear at room temperature, 400 and 650 C. Wear rates were lower than those of the cobalt alloys alone or the nickel alloy composite coating. However, oxidation limited the maximum useful temperature of the cobalt composite coating to about 650 C compared to about 900 C for the nickel composite coating.

  20. Erosion Performance of Gadolinium Zirconate-Based Thermal Barrier Coatings Processed by Suspension Plasma Spray

    NASA Astrophysics Data System (ADS)

    Mahade, Satyapal; Curry, Nicholas; Björklund, Stefan; Markocsan, Nicolaie; Nylén, Per; Vaßen, Robert

    2017-01-01

    7-8 wt.% Yttria-stabilized zirconia (YSZ) is the standard thermal barrier coating (TBC) material used by the gas turbines industry due to its excellent thermal and thermo-mechanical properties up to 1200 °C. The need for improvement in gas turbine efficiency has led to an increase in the turbine inlet gas temperature. However, above 1200 °C, YSZ has issues such as poor sintering resistance, poor phase stability and susceptibility to calcium magnesium alumino silicates (CMAS) degradation. Gadolinium zirconate (GZ) is considered as one of the promising top coat candidates for TBC applications at high temperatures (>1200 °C) due to its low thermal conductivity, good sintering resistance and CMAS attack resistance. Single-layer 8YSZ, double-layer GZ/YSZ and triple-layer GZdense/GZ/YSZ TBCs were deposited by suspension plasma spray (SPS) process. Microstructural analysis was carried out by scanning electron microscopy (SEM). A columnar microstructure was observed in the single-, double- and triple-layer TBCs. Phase analysis of the as-sprayed TBCs was carried out using XRD (x-ray diffraction) where a tetragonal prime phase of zirconia in the single-layer YSZ TBC and a cubic defect fluorite phase of GZ in the double and triple-layer TBCs was observed. Porosity measurements of the as-sprayed TBCs were made by water intrusion method and image analysis method. The as-sprayed GZ-based multi-layered TBCs were subjected to erosion test at room temperature, and their erosion resistance was compared with single-layer 8YSZ. It was shown that the erosion resistance of 8YSZ single-layer TBC was higher than GZ-based multi-layered TBCs. Among the multi-layered TBCs, triple-layer TBC was slightly better than double layer in terms of erosion resistance. The eroded TBCs were cold-mounted and analyzed by SEM.

  1. Analysis of Plasma-Sprayed Thermal Barrier Coatings With Homogeneous and Heterogeneous Bond Coats Under Spatially Uniform Cyclic Thermal Loading

    NASA Technical Reports Server (NTRS)

    Arnold, Steven M.; Pindera, Marek-Jerzy; Aboudi, Jacob

    2003-01-01

    This report summarizes the results of a numerical investigation into the spallation mechanism in plasma-sprayed thermal barrier coatings observed under spatially-uniform cyclic thermal loading. The analysis focuses on the evolution of local stress and inelastic strain fields in the vicinity of the rough top/bond coat interface during thermal cycling, and how these fields are influenced by the presence of an oxide film and spatially uniform and graded distributions of alumina particles in the metallic bond coat aimed at reducing the top/bond coat thermal expansion mismatch. The impact of these factors on the potential growth of a local horizontal delamination at the rough interface's crest is included. The analysis is conducted using the Higher-Order Theory for Functionally Graded Materials with creep/relaxation constituent modeling capabilities. For two-phase bond coat microstructures, both the actual and homogenized properties are employed in the analysis. The results reveal the important contributions of both the normal and shear stress components to the delamination growth potential in the presence of an oxide film, and suggest mixed-mode crack propagation. The use of bond coats with uniform or graded microstructures is shown to increase the potential for delamination growth by increasing the magnitude of the crack-tip shear stress component.

  2. Chemical Stability and Biological Properties of Plasma-Sprayed CaO-SiO2-ZrO2 Coatings

    NASA Astrophysics Data System (ADS)

    Liang, Ying; Xie, Youtao; Ji, Heng; Huang, Liping; Zheng, Xuebin

    2010-12-01

    In this work, calcia-stabilized zirconia powders were coated by silica derived from tetraethoxysilane (TEOS) hydrolysis. After calcining at 1400 °C, decalcification of calcia-stabilized zirconia by silica occurred and powders composed of Ca2SiO4, ZrO2, and CaZrO3 were prepared. We produced three kinds of powders with different Ca2SiO4 contents [20 wt.% (denoted as CZS2), 40 wt.% (denoted as CZS4), and 60 wt.% (denoted as CZS6)]. The obtained powders were sprayed onto Ti-6Al-4V substrates using atmospheric plasma spraying. The microstructure of the powders and coatings were analyzed. The dissolution rates of the coatings were assessed by monitoring the ions release and mass losses after immersion in Tris-HCl buffer solution. Results showed that the chemical stability of the coatings were significantly improved compared with pure calcium silicate coatings, and increased with the increase of Zr contents. The CZS4 coating showed not only good apatite-formation ability in simulated body fluid, but also well attachment and proliferation capability for the canine bone marrow stem cells. Results presented here indicate that plasma-sprayed CZS4 coating has medium dissolution rate and good biological properties, suggesting its potential use as bone implants.

  3. Effect of Sulfur Acid Corrosion on the Luminescent Intensity of Plasma-Sprayed YAG:Ce Coatings

    NASA Astrophysics Data System (ADS)

    Wang, Weize; Zeng, Peng; Wang, Hehui; Yu, Jingye; Wu, Liangmin

    2017-01-01

    In order to monitor the corrosion condition of components, plasma-sprayed YAG:Ce coating was prepared for the detection, which could develop the application of plasma spraying. The effect of sulfuric acid corrosion on the microstructure, phase composition and luminescence intensity of coatings was studied. The powder was synthesized by the high-temperature solid-state method. Microstructure and phases were characterized through using SEM and XRD, respectively. Effect of immersion time in the acid was studied on the luminescence intensity. It was found that the phase composition of the powder was dominated by YAG (Y3Al5O12). More pores could be observed in coatings with the increase in immersion time. Sprayed coatings mainly included phases of YAG and YAP (YAlO3). The position of the XRD peaks of coatings was changing during the immersion. The luminescence intensity showed the fluctuation tendency with the immersion time, which related to the coating porosity, phase composition and the migration of the diffract peak.

  4. Deposition and properties of high-velocity-oxygen-fuel and plasma-sprayed Mo-Mo2C composite coatings

    NASA Astrophysics Data System (ADS)

    Prchlik, L.; Gutleber, J.; Sampath, S.

    2001-12-01

    Molybdenum thermal-spray coatings, dispersion strengthened by molybdenum oxides and molybdenum carbides, play an important role in industrial tribological applications. Traditionally, they have been prepared by plasma and wire flame spraying. High porosity and lower cohesion strength limit their application in situations where both galling and abrasion wear is involved. In this study, high-velocity-oxygen-fuel (HVOF) deposition of molybdenum and molybdenum carbide coatings was attempted. Deposition was achieved for all powders used. Composition, microstructure, mechanical, and wear properties of the HVOF synthesized coatings were evaluated and compared with plasma-sprayed counterparts. The HVOF coatings possessed a very good abrasion resistance, whereas plasma deposits performed better in dry sliding tests. Measurements showed a close relationship between the coating surface hardness and its abrasion resistance. Results also suggested correlation between molybdenum carbide distribution in the molybdenum matrix and the sliding friction response of Mo-Mo2C coatings.

  5. High-temperature frictional wear behavior of MCrAlY-based coatings deposited by atmosphere plasma spraying

    NASA Astrophysics Data System (ADS)

    Tao, Chong; Wang, Lei; Song, Xiu

    2017-02-01

    Al2O3-Cr2O3/NiCoCrAlYTa coatings were prepared via atmosphere plasma spraying (APS). The microstructure and phase composition of the coatings were analyzed by X-ray diffraction (XRD), scanning electron microscopy (SEM), laser confocal scanning microscopy (LSCM), and transmission electron microscopy (TEM). The dry frictional wear behavior of the coatings at 500°C in static air was investigated and compared with that of 0Cr25Ni20 steel. The results show that the coatings comprise the slatted layers of oxide phases, unmelted particles, and pores. The hot abrasive resistance of the coatings is enhanced compared to that of 0Cr25Ni20, and their mass loss is approximately one-fifteenth that of 0Cr25Ni20 steel. The main wear failure mechanisms of the coatings are abrasive wear, fatigue wear, and adhesive wear.

  6. Atmospheric plasma sprayed (APS) coatings of Al2O3-TiO2 system for photocatalytic application.

    PubMed

    Stengl, V; Ageorges, H; Ctibor, P; Murafa, N

    2009-05-01

    The goal of this study is to examine the photocatalytic ability of coatings produced by atmospheric plasma spraying (APS). The plasma gun used is a common gas-stabilized plasma gun (GSP) working with a d.c. current and a mixture of argon and hydrogen as plasma-forming gas. The TiO(2) powders are particles of about 100 nm which were agglomerated to a mean size of about 55 mum, suitable for spraying. Composition of the commercial powder is 13 wt% of TiO(2) in Al(2)O(3), whereas also in-house prepared powder with the same nominal composition but with agglomerated TiO(2) and conventional fused and crushed Al(2)O(3) was sprayed. The feedstock materials used for this purpose are alpha-alumina and anatase titanium dioxide. The coatings are analyzed by scanning electron microscopy (SEM), energy dispersion probe (EDS) and X-ray diffraction. Photocatalytic degradation of acetone is quantified for various coatings. All plasma sprayed coatings show a lamellar structure on cross section, as typical for this process. Anatase titania from feedstock powder is converted into rutile titania and alpha-alumina partly to gamma-alumina. Coatings are proven to catalyse the acetone decomposition when irradiated by UV rays.

  7. Evaluation of the behavior of shrouded plasma spray coatings in the platen superheater of coal-fired boilers

    NASA Astrophysics Data System (ADS)

    Sidhu, Buta Singh; Prakash, S.

    2006-06-01

    Nickel- and cobalt-based coatings were formulated by a shrouded plasma spray process on boiler tube steels, namely, ASTM-SA210-grade A1 (GrA1), ASTM-SA213-T-11 (T11), and ASTM-SA213-T-22 (T22). The Ni-22Cr-10Al-1Y alloy powder was sprayed as a bond in each case before the final coating. The degradation behavior of the bared and coated steels was studied in the platen superheater of the coal-fired boiler. The samples were inserted through the soot blower dummy points with the help of stainless steel wires. The coatings were found to be effective in increasing resistance to degradation in the given boiler environment. The maximum protection was observed in the case of Stellite-6 (St-6) coating.

  8. Combined Mode I and Mode II Fracture of Plasma-Sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures

    NASA Technical Reports Server (NTRS)

    Choi, Sung R.; Zhu, Dongming; Miller, Robert A.

    2003-01-01

    The mode I, mode II, and combined mode I-mode II fracture behavior of ZrO2- 8wt%Y2O3 thermal barrier coatings was determined in asymmetric flexure loading at both ambient and elevated temperatures. Precracks were introduced in test specimens using the single-edge-v-notched beam (SEVNB) method incorporated with final diamond polishing to achieve sharp crack tips. A fracture envelope of KI versus KII was determined for the coating material at ambient and elevated temperatures. Propagation angles of fracture as a function of K(sub I)/K(sub II) were also determined. The mixed-mode fracture behaviors of the coating material were compared with those of monolithic advanced ceramics determined previously. The mixed-mode fracture behavior of the plasma-sprayed thermal barrier coating material was predicted in terms of fracture envelope and propagation angle using mixed-mode fracture theories.

  9. Combined Mode I and Mode II Fracture of Plasma-Sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures

    NASA Technical Reports Server (NTRS)

    Choi, Sung R.; Zhu, Dongming; Miller, Robert A.

    2003-01-01

    The mode I, mode II, and combined mode I-mode II fracture behavior of ZrO2 - 8wt%Y2O3 thermal barrier coatings was determined in asymmetric flexure loading at both ambient and elevated temperatures. Precracks were introduced in test specimens using the single-edge-v-notched beam (SEVNB) method incorporated with final diamond polishing to achieve sharp crack tips. A fracture envelope of KI versus KII was determined for the coating material at ambient and elevated temperatures. Propagation angles of fracture as a function of KI/KII were also determined. The mixed-mode fracture behaviors of the coating material were compared with those of monolithic advanced ceramics determined previously. The mixed-mode fracture behavior of the plasma- sprayed thermal barrier coating material was predicted in terms of fracture envelope and propagation angle using mixed-mode fracture theories.

  10. Failure behavior of plasma-sprayed HAp coating on commercially pure titanium substrate in simulated body fluid (SBF) under bending load.

    PubMed

    Laonapakul, Teerawat; Rakngarm Nimkerdphol, Achariya; Otsuka, Yuichi; Mutoh, Yoshiharu

    2012-11-01

    Four point bending tests with acoustic emission (AE) monitoring were conducted for evaluating failure behavior of the plasma-sprayed hydroxyapatite (HAp) top coat on commercially pure titanium (cp-Ti) plate with and without mixed HAp/Ti bond coat. Effect of immersion in simulated body fluid (SBF) on failure behavior of the coated specimen was also investigated by immersing the specimen in SBF. The AE patterns obtained from the bending test of the HAp coating specimens after a week immersion in SBF clearly showed the earlier stage of delamination and spallation of the coating layer compared to those without immersion in SBF. It was also found that the bond coating improved failure resistance of the HAp coating specimen compared to that without the bond coat. Four point bend fatigue tests under ambient and SBF environments were also conducted with AE monitoring during the entire fatigue test for investigating the influence of SBF environment on fatigue failure behavior of the HAp coating specimen with the mixed HAp/Ti bond coat. The specimens tested at a stress amplitude of 120 MPa under both ambient and SBF environments could survive up to 10⁷ cycles without spallation of HAp coating layer. The specimens tested under SBF environment and those tested under ambient environment after immersion in SBF showed shorter fatigue life compared to those tested under ambient environment without SBF immersion. Micro-cracks nucleated in the coating layer in the early stage of fatigue life and then propagated into the cp-Ti substrate in the intermediate stage, which unstably propagated to failure in the final stage. It was found from the XRD analysis that the dissolution of the co-existing phases and the precipitation of the HAp phase were taken place during immersion in SBF. During this process, the co-existing phases disappeared from the coating layer and the HAp phase fully occupied the coating layer. The degradation of bending strength and fatigue life of the HAp coating

  11. High Temperature Thermal Properties of Columnar Yttria Stabilized Zirconia Thermal Barrier Coating Performed by Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Bernard, B.; Schick, V.; Remy, B.; Quet, A.; Bianchi, L.

    2016-09-01

    Performance enhancement of gas turbines is a main issue for the aircraft industry. Over many years, a large part of the effort has been focused on the development of more insulating Thermal Barrier Coatings (TBCs). In this study, Yttria Stabilized Zirconia (YSZ) columnar structures are processed by Suspension Plasma Spraying (SPS). These structures have already demonstrated abilities to get improved thermal lifetime, similarly to standard YSZ TBCs performed by EB-PVD. Thermal diffusivity measurements coupled with differential scanning calorimetry analysis are performed from room temperature up to 1100 °C, first, on HastelloyX substrates and then, on bilayers including a SPS YSZ coating. Results show an effective thermal conductivity for YSZ performed by SPS lower than 1 W.m-1K-1 whereas EB- PVD YSZ coatings exhibit a value of 1.5 W.m-1K-1.

  12. Parametric Appraisal of Process Parameters for Adhesion of Plasma Sprayed Nanostructured YSZ Coatings Using Taguchi Experimental Design

    PubMed Central

    Mantry, Sisir; Mishra, Barada K.; Chakraborty, Madhusudan

    2013-01-01

    This paper presents the application of the Taguchi experimental design in developing nanostructured yittria stabilized zirconia (YSZ) coatings by plasma spraying process. This paper depicts dependence of adhesion strength of as-sprayed nanostructured YSZ coatings on various process parameters, and effect of those process parameters on performance output has been studied using Taguchi's L16 orthogonal array design. Particle velocities prior to impacting the substrate, stand-off-distance, and particle temperature are found to be the most significant parameter affecting the bond strength. To achieve retention of nanostructure, molten state of nanoagglomerates (temperature and velocity) has been monitored using particle diagnostics tool. Maximum adhesion strength of 40.56 MPa has been experimentally found out by selecting optimum levels of selected factors. The enhanced bond strength of nano-YSZ coating may be attributed to higher interfacial toughness due to cracks being interrupted by adherent nanozones. PMID:24288490

  13. Suspension Plasma-Sprayed ZnFe2O4 Nanostructured Coatings for ppm-Level Acetone Detection

    NASA Astrophysics Data System (ADS)

    You, Jiajun; Chen, Xia; Zheng, Bingbing; Geng, Xin; Zhang, Chao

    2017-02-01

    Zinc ferrite (ZnFe2O4) sensitive coatings have been deposited by suspension plasma spraying. The phase constitution of the coatings was characterized by x-ray diffraction while the top surface and cross-sectional morphology of the coatings were inspected by scanning electron microscopy. The response to acetone was tested with the concentration in the range of 25-500 ppm at the working temperature from 175 to 275 °C. The sensors that were deposited at an arc current of 400 A showed better performance than those at 600 A owing to small grain size and high porosity. The sensor response increased with acetone concentration. The optimized sensors showed excellent response/recovery time and selectivity to acetone at 200 °C.

  14. In vitro fatigue behaviour of vacuum plasma and detonation gun sprayed hydroxyapatite coatings.

    PubMed

    Gledhill, H C; Turner, I G; Doyle, C

    2001-06-01

    The fatigue behaviour of vacuum plasma sprayed (VPS) and detonation gun sprayed (DGUN) hydroxyapatite coatings on titanium substrates has been compared in air and in buffered Ringer's solution. There was an increase in the surface microcracking and bulk porosity of both types of coating tested in air. After 1 million cycles in Ringer's solution the VPS coatings had completely delaminated from their substrates. In contrast the DGUN coatings retained their integrity when tested up to 10 million cycles but were beginning to show signs of delamination at the interface.

  15. La2Zr2O7 (LZ) Coatings by Liquid Feedstock Plasma Spraying: The Role of Precursors

    NASA Astrophysics Data System (ADS)

    Duarte, William; Rossignol, Sylvie; Vardelle, Michel

    2014-12-01

    Solution precursor plasma spraying (SPPS) is an innovative process for obtaining finely structured coatings from metallic salt solutions. Lanthanum and zirconium precursors were studied to understand their influence on lanthanum zirconate (La2Zr2O7) synthesis by SPPS. Thermal analysis revealed that the nature of the precursor and the solvent affected mixture decomposition by changing the decomposition temperature. The surface tensions of precursor solutions in various media were investigated and revealed the influence of the nature of the counter-cation. Different solutions of precursor mixtures were used to obtain La2Zr2O7 splats on metallic substrates. A decrease in solution surface tension led to an increase in splat size. Coating mechanisms by SPPS are governed by the nature of the precursors and solvents.

  16. Mechanical Properties of Double-Layer and Graded Composite Coatings of YSZ Obtained by Atmospheric Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Carpio, Pablo; Rayón, Emilio; Salvador, María Dolores; Lusvarghi, Luca; Sánchez, Enrique

    2016-04-01

    Double-layer and graded composite coatings of yttria-stabilized zirconia were sprayed on metallic substrates by atmospheric plasma spray. The coating architecture was built up by combining two different feedstocks: one micro- and one nanostructured. Microstructural features and mechanical properties (hardness and elastic modulus) of the coatings were determined by FE-SEM microscopy and nanoindentation technique, respectively. Additional adherence and scratch tests were carried out in order to assess the failure mechanisms occurring between the layers comprising the composites. Microstructural inspection of the coatings confirms the two-zone microstructure. This bimodal microstructure which is exclusive of the layer obtained from the nanostructured feedstock negatively affects the mechanical properties of the whole composite. Nanoindentation tests suitably reproduce the evolution of mechanical properties through coatings thickness on the basis of the position and/or amount of nanostructured feedstock used in the depositing layer. Adhesion and scratch tests show the negative effect on the coating adhesion of layer obtained from the nanostructured feedstock when this layer is deposited on the bond coat. Thus, the poor integrity of this layer results in lower normal stresses required to delaminate the coating in the adhesion test as well as minor critical load registered by using the scratch test.

  17. Assessment of bone ingrowth potential of biomimetic hydroxyapatite and brushite coated porous E-beam structures.

    PubMed

    Biemond, J Elizabeth; Eufrásio, Tatiane S; Hannink, Gerjon; Verdonschot, Nico; Buma, Pieter

    2011-04-01

    The bone ingrowth potential of biomimetic hydroxyapatite and brushite coatings applied on porous E-beam structure was examined in goats and compared to a similar uncoated porous structure and a conventional titanium plasma spray coating. Specimens were implanted in the iliac crest of goats for a period of 3 (4 goats) or 15 weeks (8 goats). Mechanical implant fixation generated by bone ingrowth was analyzed by a push out test. Histomorphometry was performed to assess the bone ingrowth depth and bone implant contact. The uncoated and hydroxyapatite-coated cubic structure had significantly higher mechanical strength at the interface compared to the Ti plasma spray coating at 15 weeks of implantation. Bone ingrowth depth was significantly larger for the hydroxyapatite- and brushite-coated structures compared to the uncoated structure. In conclusion, the porous E-beam surface structure showed higher bone ingrowth potential compared to a conventional implant surface after 15 weeks of implantation. Addition of a calcium phosphate coating to the E-beam structure enhanced bone ingrowth significantly. Furthermore, the calcium phosphate coating appears to work as an accelerator for bone ingrowth.

  18. Effect of Sealing Treatment on Corrosion Resistance of Plasma-Sprayed NiCrAl/Cr2O3-8 wt.%TiO2 Coating

    NASA Astrophysics Data System (ADS)

    Zhang, Jingjing; Wang, Zehua; Lin, Pinghua; Lu, Wenhuan; Zhou, Zehua; Jiang, Shaoqun

    2011-03-01

    Plasma-sprayed ceramic coatings inherently contain pores and micro-cracks which is deleterious when performed in aggressive environment. Various methods were applied to the as-sprayed coatings in order to improve the corrosion resistance. In the investigation of this study, plasma-sprayed NiCrAl/Cr2O3-8 wt.%TiO2 coatings were sealed by epoxy resin and silicone resin, respectively. Coatings were characterized by scanning electron microscopy/energy dispersive spectroscopy (SEM/EDS), optical microscopy (OM) and x-ray diffraction (XRD). The possible corrosion mechanism was discussed. The results of salt spray test and electrochemical measurements indicated that after the sealing treatment, the porosity of coatings decreased obviously and a compact layer was formed to protect the coating from corrosion. The silicone resin proved to be more effective than epoxy resin in enhancing the corrosion resistance of the coatings used in this research.

  19. Influence of dopant on the behavior under thermal cycling of two plasma- sprayed zirconia coatings Part 2: residual stresses

    NASA Astrophysics Data System (ADS)

    Hamacha, R.; Fauchais, P.; Nardou, F.

    1997-06-01

    The evolution of coating morphology and surface residual stresses was followed for three different pow-ders: zirconia stabilized with 8 wt% yttria (YSZ), 9.9 wt% dysprosia (DSZ), and 9.8 wt% ytterbia (YbSZ). The YSZ reference powder was fused and crushed (-45 +22 μm), and the other two were agglom-erated and sintered (-90 +10 μm). According to the size distributions and manufacturing process, the plasma-sprayed YSZ particles were fully molten, resulting in dense coatings with good contact between the splats; the DSZ and, especially, the YbSZ particles were partially molten. In general, the surface residual stresses were slightly compressive before thermal cycling. The YSZ and DSZ coatings were insensitive to aging (600 h in air at room temperature), as shown by the surface stress evolution, which was not the case for YbSZ coatings. Six hundred furnace thermal cycles from 1100 °C to room temperature indicated excellent behavior of YSZ and DSZ coatings, with almost no variation of sur-face residual stresses, compared to a high dispersion for YbSZ coatings with the development of macrocracks parallel and perpendicular to the substrate within the coating.

  20. Thermal Shock Behavior of Air Plasma Sprayed CoNiCrAlY/YSZ Thermal Barrier Coatings

    NASA Astrophysics Data System (ADS)

    Liu, Zi Wei; Wu, Wei; Hua, Jia Jie; Lin, Chu Cheng; Zheng, Xue Bin; Zeng, Yi

    2014-07-01

    The structural changes and failure mechanism of thermal barrier coatings (TBCs) during thermal shock cycling were investigated. TBCs consisting of CoNiCrAlY bond coat and partially yttria-stabilized zirconia (YSZ) top coat were deposited by atmospheric plasma spraying (APS) on a nickel-based alloy substrate and its thermal shock resistance performance was evaluated. TBCs were heated at 1100°C for 15 min followed by cold water quenching to ambient temperature. Microstructural evaluation and elemental analysis of TBCs were performed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS), respectively. The crack features of YSZ coatings in TBCs during thermal shock cycling, including those of horizontal (parallel to the substrate) and vertical cracks (perpendicular to the substrate), were particularly investigated by means of SEM and image analysis. Results show that horizontal and vertical cracks have different influences on the thermal shock resistance of the coatings. Horizontal cracks that occur at the interface of YSZ and thermally growth oxidation (TGO) cause partial or large-area spalling of coatings. When vertical and horizontal cracks encounter, network segments are formed which lead to partial spalling of the coatings.

  1. Porous tantalum coatings prepared by vacuum plasma spraying enhance bmscs osteogenic differentiation and bone regeneration in vitro and in vivo.

    PubMed

    Tang, Ze; Xie, Youtao; Yang, Fei; Huang, Yan; Wang, Chuandong; Dai, Kerong; Zheng, Xuebin; Zhang, Xiaoling

    2013-01-01

    Tantalum, as a potential metallic implant biomaterial, is attracting more and more attention because of its excellent anticorrosion and biocompatibility. However, its significantly high elastic modulus and large mechanical incompatibility with bone tissue make it unsuitable for load-bearing implants. In this study, porous tantalum coatings were first successfully fabricated on titanium substrates by vacuum plasma spraying (VPS), which would exert the excellent biocompatibility of tantalum and alleviate the elastic modulus of tantalum for bone tissue. We evaluated cytocompatibility and osteogenesis activity of the porous tantalum coatings using human bone marrow stromal cells (hBMSCs) and its ability to repair rabbit femur bone defects. The morphology and actin cytoskeletons of hBMSCs were observed via electron microscopy and confocal, and the cell viability, proliferation and osteogenic differentiation potential of hBMSCs were examined quantitatively by PrestoBlue assay, Ki67 immunofluorescence assay, real-time PCR technology and ALP staining. For in vivo detection, the repaired femur were evaluated by histomorphology and double fluorescence labeling 3 months postoperation. Porous tantalum coating surfaces promoted hBMSCs adhesion, proliferation, osteogenesis activity and had better osseointegration and faster new bone formation rate than titanium coating control. Our observation suggested that the porous tantalum coatings had good biocompatibility and could enhance osseoinductivity in vitro and promote new bone formation in vivo. The porous tantalum coatings prepared by VPS is a promising strategy for bone regeneration.

  2. Thermal-Cycling Behavior of Plasma-Sprayed Partially Stabilized Zirconia Coatings on High-Density Graphite Substrate

    NASA Astrophysics Data System (ADS)

    Sure, Jagadeesh; Thyagarajan, K.; Mallika, C.; Mudali, U. Kamachi

    2015-08-01

    The thermal cycling behavior of partially stabilized zirconia (PSZ)-coated by plasma-spray process on NiCrAlY bond-coated high-density (HD) graphite substrate was investigated. Thermal cycling was carried out at 600 and 750 °C under vacuum, up to 200 cycles. Each cycle comprised a 10-min heating followed by forced air cooling for 10 min down to room temperature. Characterization of the microstructure and the phase analysis of thermal-cycled PSZ coatings by scanning electron microscopy, energy dispersive x-ray spectroscopy, x-ray diffraction (XRD), and Raman spectroscopy revealed the correlation between the microstructural/crystallographic phases and the mechanical integrity of the coating up to 200 cycles. Segmented and vertical cracks generated on the coating during thermal cycling were observed to propagate with increase in the number of cycles. Macrocracks and variations in elemental compositions were not observed until 200 cycles at 600 and 750 °C. XRD and Raman spectroscopic analysis confirmed the presence of nontransformable tetragonal phase only in all the thermal-cycled PSZ coatings, irrespective of temperature up to 200 cycles.

  3. Porous Tantalum Coatings Prepared by Vacuum Plasma Spraying Enhance BMSCs Osteogenic Differentiation and Bone Regeneration In Vitro and In Vivo

    PubMed Central

    Tang, Ze; Xie, Youtao; Yang, Fei; Huang, Yan; Wang, Chuandong; Dai, Kerong; Zheng, Xuebin; Zhang, Xiaoling

    2013-01-01

    Tantalum, as a potential metallic implant biomaterial, is attracting more and more attention because of its excellent anticorrosion and biocompatibility. However, its significantly high elastic modulus and large mechanical incompatibility with bone tissue make it unsuitable for load-bearing implants. In this study, porous tantalum coatings were first successfully fabricated on titanium substrates by vacuum plasma spraying (VPS), which would exert the excellent biocompatibility of tantalum and alleviate the elastic modulus of tantalum for bone tissue. We evaluated cytocompatibility and osteogenesis activity of the porous tantalum coatings using human bone marrow stromal cells (hBMSCs) and its ability to repair rabbit femur bone defects. The morphology and actin cytoskeletons of hBMSCs were observed via electron microscopy and confocal, and the cell viability, proliferation and osteogenic differentiation potential of hBMSCs were examined quantitatively by PrestoBlue assay, Ki67 immunofluorescence assay, real-time PCR technology and ALP staining. For in vivo detection, the repaired femur were evaluated by histomorphology and double fluorescence labeling 3 months postoperation. Porous tantalum coating surfaces promoted hBMSCs adhesion, proliferation, osteogenesis activity and had better osseointegration and faster new bone formation rate than titanium coating control. Our observation suggested that the porous tantalum coatings had good biocompatibility and could enhance osseoinductivity in vitro and promote new bone formation in vivo. The porous tantalum coatings prepared by VPS is a promising strategy for bone regeneration. PMID:23776648

  4. Effect of Carbon Black on Dielectric and Microwave Absorption Properties of Carbon Black/Cordierite Plasma-Sprayed Coatings

    NASA Astrophysics Data System (ADS)

    Su, Jinbu; Zhou, Wancheng; Liu, Yi; Qing, Yuchang; Luo, Fa; Zhu, Dongmei

    2015-06-01

    Carbon black (CB)/cordierite composite coatings with different CB contents were fabricated by a multi-function micro-plasma spraying system developed by the Second Artillery Engineering College. Scanning electron microscopy was employed to investigate the microstructure of the spray-dried powders and as-sprayed coatings. The complex permittivities of the coatings and powders with different CB contents were investigated at the frequency of 8.2-12.4 GHz. The results show that both real and imaginary part of the permittivity increase with increasing CB content, which can be ascribed to the increase of the number of micro-capacitors and the polarization centers. Reflection loss of the as-sprayed coatings with different CB contents and thicknesses was calculated according to the transmission line theory. The coating with 4.54% CB content and 3.0 mm thickness shows optical microwave absorption with a minimum reflection loss of -23.90 dB at 10.13 GHz and reflection loss less than -9 dB over the whole investigated frequency.

  5. Oxidation and Hot Corrosion Behavior of Plasma-Sprayed MCrAlY-Cr2O3 Coatings

    NASA Astrophysics Data System (ADS)

    Zhang, Tiantian; Huang, Chuanbing; Lan, Hao; Du, Lingzhong; Zhang, Weigang

    2016-08-01

    The oxidation and hot corrosion behavior of two atmospheric plasma-sprayed NiCoCrAlY-Cr2O3 and CoNiCrAlY-Cr2O3 coatings, which are primarily designed for wear applications at high temperature, were investigated in this study. The two coatings were exposed to air and molten salt (75%Na2SO4-25%NaCl) environment at 800 °C under cyclic conditions. Oxidation and hot corrosion kinetic curves were obtained by thermogravimetric technique. X-ray diffraction analysis and scanning electron microscopy with energy-dispersive x-ray spectrometry were employed to characterize the coatings' microstructure, surface oxides, and composition. The results showed that both coatings provided the necessary oxidation resistance with oxidation rates of about 1.03 × 10-2 and 1.36 × 10-2 mg/cm2 h, respectively. The excellent oxidation behavior of these two coatings is attributed to formation of protective (Ni,Co)Cr2O4 spinel on the surface, while as-deposited Cr2O3 in the coatings also acted as a barrier to diffusion of oxidative and corrosive substances. The greater presence of Co in the CoNiCrAlY-Cr2O3 coating restrained internal diffusion of sulfur and slowed down the coating's degradation. Thus, the CoNiCrAlY-Cr2O3 coating was found to be more protective than the NiCoCrAlY-Cr2O3 coating under hot corrosion condition.

  6. Cementless Hydroxyapatite Coated Hip Prostheses

    PubMed Central

    Herrera, Antonio; Mateo, Jesús; Gil-Albarova, Jorge; Lobo-Escolar, Antonio; Ibarz, Elena; Gabarre, Sergio; Más, Yolanda

    2015-01-01

    More than twenty years ago, hydroxyapatite (HA), calcium phosphate ceramics, was introduced as a coating for cementless hip prostheses. The choice of this ceramic is due to its composition being similar to organic apatite bone crystals. This ceramic is biocompatible, bioactive, and osteoconductive. These qualities facilitate the primary stability and osseointegration of implants. Our surgical experience includes the implantation of more than 4,000 cementless hydroxyapatite coated hip prostheses since 1990. The models implanted are coated with HA in the acetabulum and in the metaphyseal area of the stem. The results corresponding to survival and stability of implants were very satisfactory in the long-term. From our experience, HA-coated hip implants are a reliable alternative which can achieve long term survival, provided that certain requirements are met: good design selection, sound choice of bearing surfaces based on patient life expectancy, meticulous surgical technique, and indications based on adequate bone quality. PMID:25802848

  7. Microstructure and properties of in-flight rare-earth doped thermal barrier coatings prepared by suspension plasma spray

    NASA Astrophysics Data System (ADS)

    Gong, Stephanie

    Thermal barrier coatings with lower thermal conductivity improve the efficiency of gas turbine engines by allowing higher operating temperatures. Recent studies were shown that coatings containing a pair of rare-earth oxides with equal molar ratio have lower thermal conductivity and improved sintering resistance compared to the undoped 4-4.5 mol.% yttria-stabilized zirconia (YSZ). In the present work, rare-earth doped coatings were fabricated via suspension plasma spray by spraying YSZ powder-ethanol suspensions that contained dissolved rare-earth nitrates. The compositions of the coatings determined by inductively coupled plasma mass spectroscopy verified that 68 +/- 8% of the rare-earth nitrates added into the suspension was incorporated into the coatings. Two coatings containing different concentrations of the same dopant pair (Nd2O3/Yb2O3), and three coatings having similar concentrations of different dopant pairs (Nd 2O3/Yb2O3, Nd2O3/Gd 2O3, and Gd2O3/Yb2O 3) were produced and compared. The effect of dopant concentration and dopant pair type on the microstructure and properties of the coatings in the as-sprayed and heat treated conditions were investigated using XRD, SEM, TEM, STEM-EDX, and the laser flash method. The cross-sectional morphology of all coatings displayed columnar structure. The porosity content of the coating was found to increase with increasing dopant concentration, but did not significantly change with dopant pairs. Similarly, increasing the Nd2O3/Yb2O 3 concentration lowered the thermal conductivity of the as-sprayed coatings. Although the effect of changing dopant pair type is not as significant as increasing the dopant concentration, the coating that contained Gd2O 3/Yb2O3 exhibited the lowest conductivity compared to coatings that had other dopant pairs. Thermal conductivity measurement performed on the heat treated coatings indicated a larger conductivity increase for the rare-earth doped coatings. A detailed study on the

  8. Antibacterial mechanism of plasma sprayed Ca2ZnSi2O7 coating against Escherichia coli.

    PubMed

    Li, Kai; Xie, Youtao; Huang, Liping; Ji, Heng; Zheng, Xuebin

    2013-01-01

    In our previous work, antibacterial activity of plasma sprayed Ca(2)ZnSi(2)O(7) coating has been demonstrated. However, antibacterial mechanism of Ca(2)ZnSi(2)O(7) coating still remains undefined. In this study, Escherichia coli (E. coli), a kind of Gram-negative bacteria, was chosen to investigate the interactions between the bacterium and Ca(2)ZnSi(2)O(7) coating. Scanning electron microscopy and transmission electron microscopy micrographs exhibited that the morphologies of E. coli on the coating changed with treatment time, from initial slight disturbance to the disruption of cell wall and drastic distortion of bacterial interior where a remarkable material-light region was formed in the center and condensed deoxyribonucleic acid (DNA) molecules were found. Disturbances of cytoplasmic membrane were observed by two-photon confocal microscopy and confirmed by leakage of intracellular potassium ion (K(+)). Results suggest that the destruction of cell wall and the loss of replication ability of DNA molecules are two major reasons causing death of E. coli.

  9. Phosphor-Doped Thermal Barrier Coatings Deposited by Air Plasma Spray for In-Depth Temperature Sensing.

    PubMed

    Peng, Di; Yang, Lixia; Cai, Tao; Liu, Yingzheng; Zhao, Xiaofeng; Yao, Zhiqi

    2016-09-28

    Yttria-stabilized zirconia (YSZ)-based thermal barrier coating (TBC) has been integrated with thermographic phosphors through air plasma spray (APS) for in-depth; non-contact temperature sensing. This coating consisted of a thin layer of Dy-doped YSZ (about 40 µm) on the bottom and a regular YSZ layer with a thickness up to 300 µm on top. A measurement system has been established; which included a portable; low-cost diode laser (405 nm); a photo-multiplier tube (PMT) and the related optics. Coating samples with different topcoat thickness were calibrated in a high-temperature furnace from room temperature to around 900 °C. The results convincingly showed that the current sensor and the measurement system was capable of in-depth temperature sensing over 800 °C with a YSZ top layer up to 300 µm. The topcoat thickness was found to have a strong effect on the luminescent signal level. Therefore; the measurement accuracy at high temperatures was reduced for samples with thick topcoats due to strong light attenuation. However; it seemed that the light transmissivity of YSZ topcoat increased with temperature; which would improve the sensor's performance at high temperatures. The current sensor and the measurement technology have shown great potential in on-line monitoring of TBC interface temperature.

  10. Phosphor-Doped Thermal Barrier Coatings Deposited by Air Plasma Spray for In-Depth Temperature Sensing

    PubMed Central

    Peng, Di; Yang, Lixia; Cai, Tao; Liu, Yingzheng; Zhao, Xiaofeng; Yao, Zhiqi

    2016-01-01

    Yttria-stabilized zirconia (YSZ)-based thermal barrier coating (TBC) has been integrated with thermographic phosphors through air plasma spray (APS) for in-depth; non-contact temperature sensing. This coating consisted of a thin layer of Dy-doped YSZ (about 40 µm) on the bottom and a regular YSZ layer with a thickness up to 300 µm on top. A measurement system has been established; which included a portable; low-cost diode laser (405 nm); a photo-multiplier tube (PMT) and the related optics. Coating samples with different topcoat thickness were calibrated in a high-temperature furnace from room temperature to around 900 °C. The results convincingly showed that the current sensor and the measurement system was capable of in-depth temperature sensing over 800 °C with a YSZ top layer up to 300 µm. The topcoat thickness was found to have a strong effect on the luminescent signal level. Therefore; the measurement accuracy at high temperatures was reduced for samples with thick topcoats due to strong light attenuation. However; it seemed that the light transmissivity of YSZ topcoat increased with temperature; which would improve the sensor’s performance at high temperatures. The current sensor and the measurement technology have shown great potential in on-line monitoring of TBC interface temperature. PMID:27690037

  11. Effect of Graphite Addition on Structure and Properties of Ti(CN) Coatings Deposited by Reactive Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Mi, Pengbo; He, Jining; Zhao, Hongjian; Ni, Zenglei; Ye, Fuxing

    2016-12-01

    Ti(CN) coatings with graphite addition ranging from 0 to 50 wt.% were prepared using reactive plasma spraying technology and their microstructure, mechanical, and tribological properties were investigated using scanning and transmission electron microscopy, x-ray diffraction analysis, x-ray photoelectron spectroscopy, Vickers microhardness testing, and block-on-ring wear testing. The results showed that graphite addition resulted in crystallite size refinement and an increase in the amount of amorphous phase. The Ti(CN) coatings consisted of a mixture of Ti(CN), graphite, CN x , and amorphous phases. The hardness first increased then decreased as the graphite content was increased, with a maximum of 1450 HV0.2 for 30 wt.% graphite addition. The fracture toughness decreased from 4.38 MPa m1/2 to 2.76 MPa m1/2 with increasing graphite content. The friction coefficient decreased due to unreacted graphite embedded in the matrix. Also, the wear rate first decreased then increased, with a minimum value of 2.65 × 10-6 mm3 N-1 m-1 for 30 wt.% graphite addition. The wear mechanisms of the Ti(CN) coatings included abrasive, adhesive, and oxidation wear.

  12. Character of laser-glazed, plasma-sprayed zirconia coatings on stainless steel substrata

    NASA Technical Reports Server (NTRS)

    Fischman, G. S.; Chen, C. H.; Rigsbee, J. M.; Brown, S. D.

    1985-01-01

    Partially stabilized zirconia was applied as coatings to 316L stainless steel substrata using an 80-kw arc-plasma unit. Some of these coating-substrate systems were subsequently glazed using a 10 kw CO2 continuous-wavelength laser. SEM was used to characterize the microstructures of the coatings and coating-substrate interfaces. Results are reported and discussed.

  13. Phase Evolution upon Aging of Air-Plasma Sprayed t'-Zirconia Coatings: I-Synchrotron X-Ray Diffraction

    SciTech Connect

    Lipkin, Don M; Krogstad, Jessica A; Gao, Yan; Johnson, Curtis A; Nelson, Warren A; Levi, Carlos G

    2012-10-08

    Phase evolution accompanying the isothermal aging of free-standing air-plasma sprayed (APS) 7–8 wt% yttria-stabilized zirconia (8YSZ) thermal barrier coatings (TBCs) is described. Aging was carried out at temperatures ranging from 982°C to 1482°C in air. The high-temperature kinetics of the phase evolution from the metastable t' phase into a mixture of transformable Y-rich (cubic) and Y-lean (tetragonal) phases are documented through ambient temperature X-ray diffraction (XRD) characterization. A Hollomon–Jaffe parameter (HJP), T[27 + ln(t)], was used to satisfactorily normalize the extent of phase decomposition over the full range of times and temperatures. Comparison to vapor deposited TBCs reveal potential differences in the destabilization mechanism in APS coatings. Furthermore, the lattice parameters extracted from Rietveld refinement of the XRD patterns were used to deduce the stabilizer concentrations of the respective phases, which suggest a retrograde tetragonal solvus over the temperature range studied. In concert with a complementary microstructural study presented in Part II, this effort offers new insights into the mechanisms governing the phase evolution and raises implications for the high-temperature use of 8YSZ ceramics.

  14. Processing-structure-property relationships of thermal barrier coatings deposited using the solution precursor plasma spray process

    NASA Astrophysics Data System (ADS)

    Xie, Liangde

    This research is intended to develop a novel process, solution-precursor plasma-spray (SPPS), for the deposition of highly durable thermal barrier coatings (TBCs). In the SPPS process a solution precursor feedstock, that results in ZrO2-7 wt% Y2O3 ceramic, is injected into the plasma jet and the coating is deposited on a metal substrate. The formed coating has the following novel microstructural features: (i) ultra-fine splats, (ii) through-thickness cracks, (iii) micrometer and nanometer porosity, and (iv) interpass boundaries. The deposition mechanisms of the solution precursor droplets injected into the different regions of the plasma jet were found to be different due to large temperature variation across the plasma jet. The solution precursor droplets injected into the core of the plasma jet are deposited on the substrate as ultra-fine splats that account for around 65 volume% of the coating. The other 35 volume% of the coating includes porosity and deposits formed from the solution precursor droplets injected into other regions of the plasma jet. The optimum processing condition for highly durable TBCs was determined using Taguchi design of experiments. Meanwhile, the relationship of the microstructural features and processing parameters was revealed. During thermal cycling, the unmelted particles in the coating were observed to pyloyze and/or sinter, while no sign of sintering was observed for the ultra-fine splats. The spacing of through-thickness cracks remains in the range of 160 to 190 mum throughout the thermal cycling test. Three stages of oxidation of the bond coat were observed. Failure of the SPPS TBC starts with the crack nucleation along the unmelted particles in the top coat and the Ni, Cr, Co-rich oxides of large thickness. These cracks propagate and coalesce with thermal cycling. The extensive cracking of the rapidly formed Ni, Cr, Co-rich oxides resulting from the depletion of aluminum in the bond coat leads to the development of large

  15. AI-Li/SiCp composites and Ti-AI alloy powders and coatings prepared by a plasma spray atomization (PSA) technique

    NASA Astrophysics Data System (ADS)

    Khor, K. A.; Boey, F. Y. C.; Murakoshi, Y.; Sano, T.

    1994-06-01

    There has been increasing use of Al-Li alloys in the aerospace industry, due mainly to the low density and high elastic modulus of this material. However, the problem of low ductility and fracture toughness of this material has limited its present application to only weight- and stiffness-critical components. Development of Al-Li/ceramic composites is currently being investigated to enhance the service capabilities of this material. The Ti-Al alloy is also of interest to aerospace-type applications, engine components in particular, due to its attractive high-temperature properties. Preparation of fine powders by plasma melting of composite feedstock and coatings formed by plasma spraying was carried out to examine the effect of spray parameters on the microstructure and properties of these materials. Characterization of the powders and coatings was performed using the scanning electron microscope and image analyzer. Examination of the plasma-sprayed powders and coatings has shown that in the Al-Li/SiC composite there is melting of both materials to form a single composite particle. The SiC reinforcement was in the submicron range and contributed to additional strengthening of the composite body, which was formed by a cold isostatic press and consolidated by hot extrusion or hot forging processes. The plasma-sprayed Ti-Al powder showed four categories of microstructures: featureless, dendritic, cellular, and martensite-like.

  16. High Temperature Damping Behavior of Plasma-Sprayed Thermal Barrier and Protective Coatings

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Miller, Robert A.; Duffy, Kirsten P.; Ghosn, Louis J.

    2010-01-01

    A high temperature damping test apparatus has been developed using a high heat flux CO 2 laser rig in conjunction with a TIRA S540 25 kHz Shaker and Polytec OFV 5000 Vibrometer system. The test rig has been successfully used to determine the damping performance of metallic and ceramic protective coating systems at high temperature for turbine engine applications. The initial work has been primarily focused on the microstructure and processing effects on the coating temperature-dependence damping behavior. Advanced ceramic coatings, including multicomponent tetragonal and cubic phase thermal barrier coatings, along with composite bond coats, have also been investigated. The coating high temperature damping mechanisms will also be discussed.

  17. Investigation of mechanical properties of thermal coatings obtained during plasma spraying of powder zirconium dioxide

    NASA Astrophysics Data System (ADS)

    Ibragimov, A. R.; Ilinkova, T. A.; Shafigullin, L. N.; Saifutdinov, A. I.

    2017-01-01

    Thermal coatings of zirconia partially stabilized with yttrium, deposited by low-temperature plasma, are the basis for the thermal protection of aircraft engine. At the same time there is an actual problem of selection of coating systems “ceramic layer - underlayer” of great thickness, providing better thermal protection, but having low strength characteristics due to the accumulation of internal stresses. To determine the optimal thickness of the test method used in the 4-point bending to allow the surface coating to explore in the elastic-plastic behavior of the field of coatings and strength. Based on the experimental results established the role of underlayer in the formation of the complex mechanical properties of thermal barrier coatings. With a well formed underlayer (PVNH16U6) system becomes sensitive to a change in thickness of the coating, to optimize the response on the strength and deformation criteria. According to the results the optimum ratio of the thickness of the ceramic layer and the underlayer should be regarded as the ratio of 3-5 for which the highest strength values were obtained for all the test coating systems.

  18. Mixed Mode Fracture of Plasma Sprayed Thermal Barrier Coatings: Effects of Anisotropy and Heterogeneity

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Choi, Sung R.; Ghosn, Louis L.

    2008-01-01

    The combined mode I-mode II fracture behavior of anisotropic ZrO2-8wt%Y2O3 thermal barrier coatings was determined in asymmetric flexure loading at both ambient and elevated temperatures. A fracture envelope of KI versus KII was determined for the coating material at ambient and elevated temperatures. Propagation angles of fracture as a function of KI/KII were also determined. The mixed-mode fracture behavior of the microsplat coating material was modeled using Finite Element approach to account for anisotropy and micro cracked structures, and predicted in terms of fracture envelope and propagation angle using mixed-mode fracture theories.

  19. Evaluation of the degradation of plasma sprayed thermal barrier coatings using nano-indentation.

    PubMed

    Kim, Dae-Jin; Cho, Sung-Keun; Choi, Jung-Hun; Koo, Jae-Mean; Seok, Chang-Sung; Kim, Moon-Young

    2009-12-01

    In this study, the disk type of a thermal barrier coating (TBC) system for a gas turbine blade was isothermally aged at 1100 degrees C for various times up to 400 hours. For each aging condition, the thickness of the thermally grown oxide (TGO) was measured by optical microscope and mechanical properties such as the elastic modulus and hardness were measured by micro-indentation and nano-indentation on the cross-section of a coating specimen. In the case of micro-indentation, the mechanical properties of a Ni-base superalloy substrate and MCrAlY bond coat material did not significantly change with an increase in exposure time. In the case of nano-indentation, the gamma-Ni phase and beta-NiAl phase in the bond coat and top coat material show no significant change in their properties. However, the elastic modulus and the hardness of TGO show a remarkable decrease from 100 h to 200 h then remain nearly constant after 200 h due to the internal delamination of TBC. It has been confirmed that the nano-indentation technique is a very effective way to evaluate the degradation of a thermal barrier coating system.

  20. The Influence of Temperature on Frictional Behavior of Plasma-Sprayed NiAl-Cr2O3 Based Self-Adaptive Nanocomposite Coatings

    NASA Astrophysics Data System (ADS)

    Ramazani, M.; Ashrafizadeh, F.; Mozaffarinia, R.

    2013-10-01

    Frictional behavior of nano and hybrid-structured NiAl-Cr2O3-Ag-CNT-WS2 adaptive self-lubricant coatings was evaluated at a range of temperatures, from room temperature to 700 °C. For this purpose, hybrid structured (HS) and nanostructured (NS) composite powders with the same nominal compositions were prepared by spray drying and heat treatment techniques. A series of HS and NS coating samples were deposited on steel substrate by an atmospheric plasma spraying process. The tribological behavior of both coatings was studied from room temperature to 700 °C at 100° intervals using a custom designed high temperature wear test machine. Scanning electron microscopy was employed for the evaluation of the composite coatings and worn surfaces. Experimental results indicated that the hybrid coating had inferior tribological properties when compared to the nanostructured coating, showing the attractive frictional behavior on the basis of low friction and high wear resistance; the NS coating possessed a more stable friction coefficient in the temperature range of 25-700 °C against alumina counterface. Microstructural examinations revealed more uniformity in NS plasma-sprayed coatings.

  1. Nanoindentation Study of Phase-pure Highly Crystalline Hydroxyapatite Coatings Deposited by Microplasma Spraying

    PubMed Central

    Dey, Arjun; Mukhopadhyay, Anoop Kumar

    2015-01-01

    The present contribution has originated from a critical biomedical engineering issue e.g., loosening of metallic prostheses fixed with poly(methylmethylacrylate) (PMMA) bone cement especially in the case of hip joint replacement which ultimately forces the patient to undergo a revision surgery. Subsequently surgeons invented a cementless fixation technology introducing a bioactive hydroxyapatite (HAp) coating to the metallic implant surface. A wide variety of different coating methods have been developed to make the HAp coating on metallic implants more reliable; of which ultimately the plasma spraying method has been commercially accepted. However, the story was not yet finished at all, as many questions were raised regarding coating adherence, stability and bio-functionality in both in vitro and in vivo environments. Moreover, it has been now realized that the conventional high power plasma spraying (i.e. conventional atmospheric plasma spraying, CAPS) coating method creates many disadvantages in terms of phase impurity; reduced porosity limiting osseointegration and residual stresses which ultimately lead to inadequate mechanical properties and delamination of the coating. Further, poor crystallinity of HAp deposited by CAPS accelerates the rate of bioresorption, which may cause poor adhesion due to quick mass loss of HAp coatings. Therefore, in the present work a very recently developed method e.g., low power microplasma spraying method was utilized to coat HAp on SS316L substrates to minimize the aforementioned problems associated with commercial CAPS HAp coatings. Surgical grade SS316L has been chosen as the substrate material because it is more cost effective than Ti6Al4V and CoCrMo alloys. PMID:25893017

  2. Nanostructure of biocompatible titania/hydroxyapatite coatings

    NASA Astrophysics Data System (ADS)

    Fomin, Aleksandr A.; Rodionov, Igor V.; Steinhauer, Aleksey B.; Fomina, Marina A.; Petrova, Natalia V.; Zakharevich, Andrey M.; Skaptsov, Aleksandr A.; Gribov, Andrey N.; Atkin, Vsevolod S.

    2014-01-01

    The article describes prospective composite biocompatible titania coatings modified with hydroxyapatite nanoparticles and obtained on intraosseous implants fabricated from commercially pure titanium VT1-00. Consistency changes of morphological characteristics, crystalline structure, physical and mechanical properties and biocompatibility of experimental titanium implant coatings obtained by the combination of oxidation and surface modification with hydroxyapatite during induction heat treatment are defined.

  3. Friction and Wear Characteristics of a Modified Composite Solid Lubricant Plasma Spray Coating

    NASA Technical Reports Server (NTRS)

    Stanford, M. K.; DellaCorte, C.

    2004-01-01

    LCR304 is a solid lubricant coating composed of Ni-10Cr, Cr2O3, BaF2-CaF2 and Ag and developed for dimensional stability in high temperature air. This coating is a modification of PS304, which differs in that the Ni-Cr constituent contains 20wt% Cr. The tribological characteristics of LCR304 were evaluated by pin-on-disk and foil air bearing rig testing from 25 to 650 C and compared to previous test results with PS304. For both tests, the friction coefficient decreased as temperature increased from 25 to 650 C. Wear generally decreased with increasing temperature for all pin-on-disk tests. LCR304 coated components produced the least wear of Inconel X-750 counterface materials at 427 and 650 C. These results indicate that the LCR304 coating has potential as a replacement for PS304 in, for example, low cycle (minimum wear) applications where dimensional stability is imperative.

  4. Development and Oxidation Resistance of Plasma Sprayed Mo(Si,Al)2 Coating on Nbss/Nb5Si3 in Situ Composites

    NASA Astrophysics Data System (ADS)

    Yao, Dendzun; Wei, Haixia; Zhou, Chungen

    A Mo(Si,Al)2 coating is developed to protect Nbss/Nb5Si3 in situ composite by plasma spraying. The binary layers of this coating consist of an inner interdiffusion layer surrounded by Mo(Si,Al)2 layer with C40 crystal structure. After oxidation at 1250°C for 100h, Mo(Si,Al)2 coating exhibited an excellent protection against oxidation and good adherence to substrate. The oxidation curve followed parabolic law and even after oxidation at high temperature for 100h, the weight gain per unit area of Mo(Si,Al)2 coating is 8.24mg/cm2. No evident spalling of coating to substrate was observed but a continuous and compact layer of Al2O3 was formed on coating surface to prevent oxidation below coating and substrate.

  5. Thermal Conductivity and Erosion Durability of Composite Two-Phase Air Plasma Sprayed Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Schmitt, Michael P.; Rai, Amarendra K.; Zhu, Dongming; Dorfman, Mitchell R.; Wolfe, Douglas E.

    2015-01-01

    To enhance efficiency of gas turbines, new thermal barrier coatings (TBCs) must be designed which improve upon the thermal stability limit of 7 wt% yttria stabilized zirconia (7YSZ), approximately 1200 C. This tenant has led to the development of new TBC materials and microstructures capable of improved high temperature performance. This study focused on increasing the erosion durability of cubic zirconia based TBCs, traditionally less durable than the metastable t' zirconia based TBCs. Composite TBC microstructures composed of a low thermal conductivity/high temperature stable cubic Low-k matrix phase and a durable t' Low-k secondary phase were deposited via APS. Monolithic coatings composed of cubic Low-k and t' Low-k were also deposited, in addition to a 7YSZ benchmark. The thermal conductivity and erosion durability were then measured and it was found that both of the Low-k materials have significantly reduced thermal conductivities, with monolithic t' Low-k and cubic Low-k improving upon 7YSZ by approximately 13 and approximately 25%, respectively. The 40 wt% t' Low-k composite (40 wt% t' Low-k - 60 wt% cubic Low-k) showed a approximately 22% reduction in thermal conductivity over 7YSZ, indicating even at high levels, the t' Low-k secondary phase had a minimal impact on thermal in the composite coating. It was observed that a mere 20 wt% t' Low-k phase addition can reduce the erosion of a cubic Low-k matrix phase composite coating by over 37%. Various mixing rules were then investigated to assess this non-linear composite behavior and suggestions were made to further improve erosion durability.

  6. Failure Behavior of Plasma-Sprayed Yttria-Stabilized Zirconia Thermal Barrier Coatings Under Three-Point Bending Test via Acoustic Emission Technique

    NASA Astrophysics Data System (ADS)

    Wang, L.; Ni, J. X.; Shao, F.; Yang, J. S.; Zhong, X. H.; Zhao, H. Y.; Liu, C. G.; Tao, S. Y.; Wang, Y.; Li, D. Y.

    2017-01-01

    In this paper, the failure behavior of plasma-sprayed yttria-stabilized zirconia thermal barrier coatings fabricated by atmospheric plasma spraying (APS-TBCs) under three-point bending (3PB) test has been characterized via acoustic emission (AE) technique. Linear positioning method has been adopted to monitor dynamic failure process of the APS-TBCs under 3PB test. The investigation results indicate that the variation of AE parameters (AE event counts, amplitudes and AE energy) corresponds well with the change of stress-strain curve of the loading processes. The failure mechanism was analyzed based on the characteristics of AE parameters. The distribution of frequency of crack propagation has been obtained. The AE signals came from two aspects: i.e., plastic deformation of substrates, initiation and propagation of the cracks in the coatings. The AE analysis combined with cross-sectional observation has indicated that many critical cracks initiate at the surface of the top-coat. And some main cracks tend to propagate toward the substrate/bond-coat interface. The actual failure mechanism of the APS-TBCs under 3PB test is attributed to the debonding of metallic coating from the substrates and the propagation of the horizontal crack along the substrate/bond-coat interface under the action of flexural moment.

  7. Comparison of Thermal Properties of Thermal Barrier Coating Deposited on IN738 Using Standard Air Plasma Spray with 100HE Plasma Spray System

    SciTech Connect

    Uppu, Nalini; Mensah, Patrick F.; Ofori, Daniel

    2006-07-31

    Thermal barrier coatings (TBCs) have low thermal conductivity values and have a primary benefit of providing an insulating layer that reduces the coated substrate temperature and mitigates the effects of hot streaking or uneven temperature distributions. Thermal conductivity, k, is a thermo-physical property that can be derived from the thermal diffusivity, α, of the specimen. It can be obtained from the formula k = α cp ρ, where cp is specific heat and ρ is the density of the material. Thermal conductivity, k, describes the quantity of heat that passes through a unit area of sample in unit time with a temperature gradient present. This thermal property of TBCs can be measured by flash method in which a nearly instantaneous pulse of energy (usually laser or other discharge source) is input to the frontal surface of a material sample and the temperature changes are measured on back side of sample with and INSb infrared detector as shown in Fig.1. A laser flash test has the advantage of being fast while providing values with excellent accuracy and reproducibility. In this study, an instantaneous triangular heat pulse from a laser heat flash system (FL5000) made by Anter corporation, Pittsburgh, PA was used. The technique satisfies the ASTM E 1461. The test method can measure thermal diffusivity values ranging from 10-7 to 10-3 m2/s from temperatures 75 to 2800 K.

  8. Determination of Scattering and Absorption Coefficients for Plasma-Sprayed Yttria-Stabilized Zirconia Thermal Barrier Coatings at Elevated Temperatures

    NASA Technical Reports Server (NTRS)

    Eldridge, Jeffrey I.; Spuckler, Charles M.; Markham, James R.

    2009-01-01

    The temperature dependence of the scattering and absorption coefficients for a set of freestanding plasma-sprayed 8 wt% yttria-stabilized zirconia (8YSZ) thermal barrier coatings (TBCs) was determined at temperatures up to 1360 C in a wavelength range from 1.2 micrometers up to the 8YSZ absorption edge. The scattering and absorption coefficients were determined by fitting the directional-hemispherical reflectance and transmittance values calculated by a four-flux Kubelka Munk method to the experimentally measured hemispherical-directional reflectance and transmittance values obtained for five 8YSZ thicknesses. The scattering coefficient exhibited a continuous decrease with increasing wavelength and showed no significant temperature dependence. The scattering is primarily attributed to the relatively temperature-insensitive refractive index mismatch between the 8YSZ and its internal voids. The absorption coefficient was very low (less than 1 per centimeter) at wavelengths between 2 micrometers and the absorption edge and showed a definite temperature dependence that consisted of a shift of the absorption edge to shorter wavelengths and an increase in the weak absorption below the absorption edge with increasing temperature. The shift in the absorption edge with temperature is attributed to strongly temperature-dependent multiphonon absorption. While TBC hemispherical transmittance beyond the absorption edge can be predicted by a simple exponential decrease with thickness, below the absorption edge, typical TBC thicknesses are well below the thickness range where a simple exponential decrease in hemispherical transmittance with TBC thickness is expected. [Correction added after online publication August 11, 2009: "edge to a shorter wavelengths" has been updated as edge to shorter wavelengths."

  9. Neutron diffraction residual strain measurements in nanostructured hydroxyapatite coatings for orthopaedic implants.

    PubMed

    Ahmed, R; Faisal, N H; Paradowska, A M; Fitzpatrick, M E; Khor, K A

    2011-11-01

    The failure of an orthopaedic implant can be initiated by residual strain inherent to the hydroxyapatite coating (HAC). Knowledge of the through-thickness residual strain profile in the thermally sprayed hydroxyapatite coating/substrate system is therefore important in the development of a new generation of orthopaedic implants. As the coating microstructure is complex, non-destructive characterization of residual strain, e.g. using neutron diffraction, provides a useful measure of through thickness strain profile without altering the stress field. This first detailed study using a neutron diffraction technique, non-destructively evaluates the through thickness strain measurement in nanostructured hydroxyapatite plasma sprayed coatings on a titanium alloy substrate (as-sprayed, heat treated, and heat treated then soaked in simulated body fluid (SBF)). The influence of crystallographic plane orientation on the residual strain measurement is shown to indicate texturing in the coating. This texturing is expected to influence both the biological and fracture response of HA coatings. Results are discussed in terms of the influence of heat-treatment and SBF on the residual stress profile for these biomedical coatings. The results show that the through thickness residual strain in all three coatings was different for different crystallographic planes but was on average tensile. It is also concluded that the heat-treatment and simulated body fluid exposure had a significant effect on the residual strain profile in the top layers of HAC.

  10. Plasma-Sprayed Refractory Oxide Coatings on Silicon-Base Ceramics

    NASA Technical Reports Server (NTRS)

    Tewari, Surendra

    1997-01-01

    Silicon-base ceramics are promising candidate materials for high temperature structural applications such as heat exchangers, gas turbines and advanced internal combustion engines. Composites based on these materials are leading candidates for combustor materials for HSCT gas turbine engines. These materials possess a combination of excellent physical and mechanical properties at high temperatures, for example, high strength, high toughness, high thermal shock resistance, high thermal conductivity, light weight and excellent oxidation resistance. However, environmental durability can be significantly reduced in certain conditions such as when molten salts, H2 or water vapor are present. The oxidation resistance of silicon-base materials is provided by SiO2 protective layer. Molten salt reacts with SiO2 and forms a mixture of SiO2 and liquid silicate at temperatures above 800C. Oxygen diffuses more easily through the chemically altered layer, resulting in a catastrophic degradation of the substrate. SiC and Si3N4 are not stable in pure H2 and decompose to silicon and gaseous species such as CH4, SiH, SiH4, N2, and NH3. Water vapor is known to slightly increase the oxidation rate of SiC and Si3N4. Refractory oxides such as alumina, yttria-stabilized zirconia, yttria and mullite (3Al2O3.2SiO2) possess excellent environmental durability in harsh conditions mentioned above. Therefore, refractory oxide coatings on silicon-base ceramics can substantially improve the environmental durability of these materials by acting as a chemical reaction barrier. These oxide coatings can also serve as a thermal barrier. The purpose of this research program has been to develop refractory oxide chemical/thermal barrier coatings on silicon-base ceramics to provide extended temperature range and lifetime to these materials in harsh environments.

  11. Real-Time Protein and Cell Binding Measurements on Hydroxyapatite Coatings

    PubMed Central

    Vilardell, A. M.; Cinca, N.; Jokinen, A.; Garcia-Giralt, N.; Dosta, S.; Cano, I. G.; Guilemany, J. M.

    2016-01-01

    Although a lot of in vitro and in vivo assays have been performed during the last few decades years for hydroxyapatite bioactive coatings, there is a lack of exploitation of real-time in vitro interaction measurements. In the present work, real-time interactions for a plasma sprayed hydroxyapatite coating were measured by a Multi-Parametric Surface Plasmon Resonance (MP-SPR), and the results were compared with standard traditional cell viability in vitro assays. MP-SPR is proven to be suitable not only for measurement of molecule–molecule interactions but also molecule–material interaction measurements and cell interaction. Although SPR is extensively utilized in interaction studies, recent research of protein or cell adsorption on hydroxyapatite coatings for prostheses applications was not found. The as-sprayed hydroxyapatite coating resulted in 62.4% of crystalline phase and an average thickness of 24 ± 6 μm. The MP-SPR was used to measure lysozyme protein and human mesenchymal stem cells interaction to the hydroxyapatite coating. A comparison between the standard gold sensor and Hydroxyapatite (HA)-plasma coated sensor denoted a clearly favourable cell attachment on HA coated sensor as a significantly higher signal of cell binding was detected. Moreover, traditional cell viability and proliferation tests showed increased activity with culture time indicating that cells were proliferating on HA coating. Cells show homogeneous distribution and proliferation along the HA surface between one and seven days with no significant mortality. Cells were flattened and spread on rough surfaces from the first day, with increasing cytoplasmatic extensions during the culture time. PMID:27618911

  12. Structural analysis of hydroxyapatite coatings on titanium.

    PubMed

    Ducheyne, P; Van Raemdonck, W; Heughebaert, J C; Heughebaert, M

    1986-03-01

    Hydroxyapatite from two sources was electrophoretically deposited onto flat titanium plate material. Depending upon the deposition conditions various changes in the structure of the ceramic were identified. A well-adhering Ti-P compound was present at the interface. Hydroxyapatite oxygenated to various degrees and tetracalcium phosphate were reproducibly formed in the coating.

  13. Detection of segmentation cracks in top coat of thermal barrier coatings during plasma spraying by non-contact acoustic emission method.

    PubMed

    Ito, Kaita; Kuriki, Hitoshi; Araki, Hiroshi; Kuroda, Seiji; Enoki, Manabu

    2014-06-01

    Numerous cracks can be observed in the top coat of thermal barrier coatings (TBCs) deposited by the atmospheric plasma spraying (APS) method. These cracks can be classified into vertical and horizontal ones and they have opposite impact on the properties of TBCs. Vertical cracks reduce the residual stress in the top coat and provide strain tolerance. On the contrary, horizontal cracks trigger delamination of the top coat. However, monitoring methods of cracks generation during APS are rare even though they are strongly desired. Therefore, an in situ, non-contact and non-destructive evaluation method for this objective was developed in this study with the laser acoustic emission (AE) technique by using laser interferometers as a sensor. More AE events could be detected by introducing an improved noise reduction filter and AE event detection procedures with multiple thresholds. Generation of vertical cracks was successfully separated from horizontal cracks by a newly introduced scanning pattern of a plasma torch. Thus, generation of vertical cracks was detected with certainty by this monitoring method because AE events were detected only during spraying and a positive correlation was observed between the development degree of vertical cracks and the total AE energy in one experiment.

  14. Detection of segmentation cracks in top coat of thermal barrier coatings during plasma spraying by non-contact acoustic emission method

    PubMed Central

    Ito, Kaita; Kuriki, Hitoshi; Araki, Hiroshi; Kuroda, Seiji; Enoki, Manabu

    2014-01-01

    Numerous cracks can be observed in the top coat of thermal barrier coatings (TBCs) deposited by the atmospheric plasma spraying (APS) method. These cracks can be classified into vertical and horizontal ones and they have opposite impact on the properties of TBCs. Vertical cracks reduce the residual stress in the top coat and provide strain tolerance. On the contrary, horizontal cracks trigger delamination of the top coat. However, monitoring methods of cracks generation during APS are rare even though they are strongly desired. Therefore, an in situ, non-contact and non-destructive evaluation method for this objective was developed in this study with the laser acoustic emission (AE) technique by using laser interferometers as a sensor. More AE events could be detected by introducing an improved noise reduction filter and AE event detection procedures with multiple thresholds. Generation of vertical cracks was successfully separated from horizontal cracks by a newly introduced scanning pattern of a plasma torch. Thus, generation of vertical cracks was detected with certainty by this monitoring method because AE events were detected only during spraying and a positive correlation was observed between the development degree of vertical cracks and the total AE energy in one experiment. PMID:27877683

  15. Feedback enhanced plasma spray tool

    DOEpatents

    Gevelber, Michael Alan; Wroblewski, Donald Edward; Fincke, James Russell; Swank, William David; Haggard, Delon C.; Bewley, Randy Lee

    2005-11-22

    An improved automatic feedback control scheme enhances plasma spraying of powdered material through reduction of process variability and providing better ability to engineer coating structure. The present inventors discovered that controlling centroid position of the spatial distribution along with other output parameters, such as particle temperature, particle velocity, and molten mass flux rate, vastly increases control over the sprayed coating structure, including vertical and horizontal cracks, voids, and porosity. It also allows improved control over graded layers or compositionally varying layers of material, reduces variations, including variation in coating thickness, and allows increasing deposition rate. Various measurement and system control schemes are provided.

  16. Effect of Critical Plasma Spray Parameters on Microstructure and Microwave Absorption Property of Ti3SiC2/Cordierite Coatings

    NASA Astrophysics Data System (ADS)

    Su, Jinbu; Zhou, Wancheng; Wang, Hongyu; Liu, Yi; Qing, Yuchang; Luo, Fa; Zhu, Dongmei; Zhou, Liang

    2016-04-01

    Ti3SiC2/cordierite coatings with different critical plasma spray parameters (CPSP) were fabricated via atmospheric plasma spraying method. The microstructure and phase constitution of the as-sprayed Ti3SiC2/cordierite coatings were characterized. The effects of CPSP conditions on the electromagnetic shielding, and dielectric and microwave absorption properties of coatings in the frequency of 8.2-12.4 GHz were also measured and investigated. The results showed that both real and imaginary part of the complex permittivity decrease with increasing CPSP values, which can be ascribed to the decomposition of some Ti3SiC2 into TiC. The calculated reflection loss of the as-sprayed Ti3SiC2/cordierite coatings with different CPSP conditions and thicknesses indicates that coatings with CPSP 0.3, 0.35, and 0.425 exhibit excellent microwave absorption property in the thickness of 1.5 mm. In order to broaden the bandwidth of the coatings, a double-layer coating system was designed. The calculated reflection loss results show that when the thickness of matching layer is 0.3 mm and the thickness of absorbing layer is 1.5 mm, the double-layer coating system shows a proper microwave absorption property with a minimum absorption value of -17.37 dB at 9.67 GHz and a absorption bandwidth (RL less than -5 dB) of 4.16 GHz in the investigated frequency.

  17. Reducing bacteria and macrophage density on nanophase hydroxyapatite coated onto titanium surfaces without releasing pharmaceutical agents.

    PubMed

    Bhardwaj, Garima; Yazici, Hilal; Webster, Thomas J

    2015-05-14

    Reducing bacterial density on titanium implant surfaces has been a major concern because of the increasing number of nosocomial infections. Controlling the inflammatory response post implantation has also been an important issue for medical devices due to the detrimental effects of chronic inflammation on device performance. It has recently been demonstrated that manipulating medical device surface properties including chemistry, roughness and wettability can control both infection and inflammation. Here, we synthesized nanophase (that is, materials with one dimension in the nanoscale) hydroxyapatite coatings on titanium to reduce bacterial adhesion and inflammatory responses (as measured by macrophage functions) and compared such results to bare titanium and plasma sprayed hydroxyapatite titanium coated surfaces used clinically today. This approach is a pharmaceutical-free approach to inhibit infection and inflammation due to the detrimental side effects of any drug released in the body. Here, nanophase hydroxyapatite was synthesized in sizes ranging from 110-170 nm and was subsequently coated onto titanium samples using electrophoretic deposition. Results indicated that smaller nanoscale hydroxyapatite features on titanium surfaces alone decreased bacterial attachment in the presence of gram negative (P. aeruginosa), gram positive (S. aureus) and ampicillin resistant gram-negative (E. coli) bacteria as well as were able to control inflammatory responses; properties which should lead to their further investigation for improved medical applications.

  18. Reducing bacteria and macrophage density on nanophase hydroxyapatite coated onto titanium surfaces without releasing pharmaceutical agents

    NASA Astrophysics Data System (ADS)

    Bhardwaj, Garima; Yazici, Hilal; Webster, Thomas J.

    2015-04-01

    Reducing bacterial density on titanium implant surfaces has been a major concern because of the increasing number of nosocomial infections. Controlling the inflammatory response post implantation has also been an important issue for medical devices due to the detrimental effects of chronic inflammation on device performance. It has recently been demonstrated that manipulating medical device surface properties including chemistry, roughness and wettability can control both infection and inflammation. Here, we synthesized nanophase (that is, materials with one dimension in the nanoscale) hydroxyapatite coatings on titanium to reduce bacterial adhesion and inflammatory responses (as measured by macrophage functions) and compared such results to bare titanium and plasma sprayed hydroxyapatite titanium coated surfaces used clinically today. This approach is a pharmaceutical-free approach to inhibit infection and inflammation due to the detrimental side effects of any drug released in the body. Here, nanophase hydroxyapatite was synthesized in sizes ranging from 110-170 nm and was subsequently coated onto titanium samples using electrophoretic deposition. Results indicated that smaller nanoscale hydroxyapatite features on titanium surfaces alone decreased bacterial attachment in the presence of gram negative (P. aeruginosa), gram positive (S. aureus) and ampicillin resistant gram-negative (E. coli) bacteria as well as were able to control inflammatory responses; properties which should lead to their further investigation for improved medical applications.

  19. Plasma-sprayed metal-glass and metal-glass fluoride coatings for lubrication to 900 C

    NASA Technical Reports Server (NTRS)

    Sliney, H. E.

    1973-01-01

    Plasma-sprayed composites, which have good oxidation-resistance and self-lubricating characteritics to 900 C, were developed. The composites are a nichrome matrix containing dispersed glass for oxidation protection and calcium fluoride for lubrication; they are applied to bearing surfaces by plasma spraying layers about 0.050 centimeters thick which are then machined to 0.025 centimeters. Oscillating bearing tests were performed in air to 900 C at unit radial loads up to 3.5 x 10 to the 7th power N/sq M (5000 psi) and a thrust load of 1960N (440 lbs). Bearings with a composite liner in the bore were in good condition after over 50,000 oscillating cycles accumulated during repeated, bearing temperatures cycles between 25 and 900 C.

  20. Furnace Cyclic Behavior of Plasma-Sprayed Zirconia-Yttria and Multi-Component Rare Earth Oxide Doped Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Zhu, Dongming; Nesbitt, James A.; McCue, Terry R.; Barrett, Charles A.; Miller, Robert A.

    2002-01-01

    Ceramic thermal barrier coatings will play an increasingly important role in advanced gas turbine engines because of their ability to enable further increases in engine temperatures. However, the coating performance and durability become a major concern under the increasingly harsh thermal cycling conditions. Advanced zirconia- and hafnia-based cluster oxide thermal barrier coatings with lower thermal conductivity and improved thermal stability are being developed using a high-heat-flux laser-rig based test approach. Although the new composition coatings were not yet optimized for cyclic durability, an initial durability screening of numerous candidate coating materials was carried out using conventional furnace cyclic tests. In this paper, furnace thermal cyclic behavior of the advanced plasma-sprayed zirconia-yttria-based thermal barrier coatings that were co-doped with multi-component rare earth oxides was investigated at 1163 C using 45 min hot cycles. The ceramic coating failure mechanisms were studied by using scanning electron microscopy combined with X-ray diffraction phase analysis after the furnace tests. The coating cyclic lifetime will be discussed in relation to coating phase structures, total dopant concentrations, and other properties.

  1. Development of a Thermal Transport Database for Air Plasma Sprayed ZrO2 ? Y2O3 Thermal Barrier Coatings

    SciTech Connect

    Wang, Hsin; Dinwiddie, Ralph Barton; Porter, Wallace D

    2010-01-01

    Thermal Diffusivities of Air Plasma Sprayed (APS) thermal barrier coatings (TBCs) are measured by the laser flash method. The data are used to calculate thermal conductivity of TBCs when provided with density and specific heat data. Due to the complicated microstructure and other processing related parameters, thermal diffusivity of TBCs can vary as much as three to four fold. Data collected from over 200 free-standing ZrO2 7-8 wt%Y2O3 TBCs are presented. The large database gives a clear picture of the expected band of thermal diffusivity values. When this band is used as reference for thermal diffusivity of a specific TBC, the thermal transport property of TBC can be more precisely described. The database is intended to serve researchers and manufacturers of TBCs as a valuable source for evaluating their coatings.

  2. Hydroxyapatite-nanotube composites and coatings for orthopedic applications

    NASA Astrophysics Data System (ADS)

    Lahiri, Debrupa

    Hydroxyapatite (HA) has received wide attention in orthopedics, due to its biocompatibility and osseointegration ability. Despite these advantages, the brittle nature and low fracture toughness of HA often results in rapid wear and premature fracture of implant. Hence, there is a need to improve the fracture toughness and wear resistance of HA without compromising its biocompatibility. The aim of the current research is to explore the potential of nanotubes as reinforcement to HA for orthopedic implants. HA- 4 wt.% carbon nanotube (CNT) composites and coatings are synthesized by spark plasma sintering and plasma spraying respectively, and investigated for their mechanical, tribological and biological behavior. CNT reinforcement improves the fracture toughness (>90%) and wear resistance (>66%) of HA for coating and free standing composites. CNTs have demonstrated a positive influence on the proliferation, differentiation and matrix mineralization activities of osteoblasts, during in-vitro biocompatibility studies. In-vivo exposure of HA-CNT coated titanium implant in animal model (rat) shows excellent histocompatibility and neobone integration on the implant surface. The improved osseointegration due to presence of CNTs in HA is quantified by the adhesion strength measurement of single osteoblast using nano-scratch technique. Considering the ongoing debate about cytotoxicity of CNTs in the literature, the present study also suggests boron nitride nanotube (BNNT) as an alternative reinforcement. BNNT with the similar elastic modulus and strength as CNT, were added to HA. The resulting composite having 4 wt.% BNNTs improved the fracture toughness (˜85%) and wear resistance (˜75%) of HA in the similar range as HA-CNT composites. BNNTs were found to be non-cytotoxic for osteoblasts and macrophages. In-vitro evaluation shows positive role of BNNT in osteoblast proliferation and viability. Apatite formability of BNNT surface in ˜4 days establishes its osseointegration

  3. Hot isostatic pressing-processed hydroxyapatite-coated titanium implants: light microscopic and scanning electron microscopy investigations.

    PubMed

    Wie, H; Herø, H; Solheim, T

    1998-01-01

    Hot isostatic pressing (HIP) was used in a new procedure to produce hydroxyapatite (HA) coatings on a commercially pure titanium (cpTi) substrate for osseous implantation. Eighteen HIP-processed HA-coated implants were placed in the inferior border of the mandibles in 2 Labrador retriever dogs and left submerged for 3 months. As control specimens, 12 sandblasted cpTi implants were placed in the same mandibles and, to compare the bone reaction, 2 additional plasma-sprayed HA-coated implants (Integral) were placed. Tissue reactions at the bony interfaces of the implants were studied in ground sections with the implants in situ, using ordinary, fluorescent, and polarized light microscopy and scanning electron microscopy (SEM). The HIP-processed HA coatings displayed an increased density in light microscopy and SEM as compared to plasma-sprayed coatings. Direct bone-implant contact was found in all 3 types of surfaces. However, the production of new bone was far more abundant for the HA-coated implants than for sandblasted cpTi implants. The presence of bone-forming and bone-resorbing cells indicated active bone remodeling in the interface area at 3 months after implant placement. The present results support the view that epitaxial bone growth may occur from the HA-coated implant surface. It was concluded that the increased density of the present HIP-processed HA material does not reduce the bioactive properties of the coatings.

  4. Microstructure and Wear Behavior of Atmospheric Plasma-Sprayed AlCoCrFeNiTi High-Entropy Alloy Coating

    NASA Astrophysics Data System (ADS)

    Tian, Li-Hui; Xiong, Wei; Liu, Chuan; Lu, Sheng; Fu, Ming

    2016-12-01

    Due to the advantages such as high strength, high hardness and good wear resistance, high-entropy alloys (HEAs) attracted more and more attentions in recent decades. However, most reports on HEAs were limited to bulk materials. Although a few of studies on atmospheric plasma-sprayed (APS) HEA coatings were carried out, the wear behavior, especially the high-temperature wear behavior of those coatings has not been investigated till now. Therefore, in this study, APS was employed to deposit AlCoCrFeNiTi high-entropy alloy coating using mechanically alloyed AlCoCrFeNiTi powder as the feedstock. The phase structure of the initial powder, the feedstock powder and the as-sprayed coating was examined by an x-ray diffractometer. The surface morphology of the feedstock powder and the microstructure of the as-sprayed coating were analyzed by field emission scanning electron microscopy and energy-dispersive spectroscopy. The bonding strength and the microhardness of the as-sprayed coating were tested. The wear behavior of the coating at 25, 500, 700 and 900 °C was investigated by analysis of the wear surface morphology and measurements of the volume wear rate and the coefficient of friction.

  5. Microstructure studies of air-plasma-spray-deposited CoNiCrAlY coatings before and after thermal cyclic loading for high-temperature application

    NASA Astrophysics Data System (ADS)

    Kumar, Dipak; Pandey, K. N.; Das, Dipak Kumar

    2016-08-01

    In the present study, bond-coats for thermal barrier coatings were deposited via air plasma spraying (APS) techniques onto Inconel 800 and Hastelloy C-276 alloy substrates. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), and atomic force microscopy (AFM) were used to investigate the phases and microstructure of the as-sprayed, APS-deposited CoNiCrAlY bond-coatings. The aim of this work was to study the suitability of the bond-coat materials for high temperature applications. Confirmation of nanoscale grains of the γ/γ'-phase was obtained by TEM, high-resolution TEM, and AFM. We concluded that these changes result from the plastic deformation of the bond-coat during the deposition, resulting in CoNiCrAlY bond-coatings with excellent thermal cyclic resistance suitable for use in high-temperature applications. Cyclic oxidative stability was observed to also depend on the underlying metallic alloy substrate.

  6. Effect of chemical composition on hydrophobicity and zeta potential of plasma sprayed HA/CaO-P2O5 glass coatings.

    PubMed

    Ferraz, M P; Monteiro, F J; Serro, A P; Saramago, B; Gibson, I R; Santos, J D

    2001-12-01

    Multilayered plasma sprayed coatings on the surface of Ti-6Al-4V alloys have been prepared, which were composed of an underlayer of HA and a surface layer of a CaO-P2O5 glass-HA composite, with 2 or 4wt% of glass. Contact angle and surface tension variation with time, for both water and a protein solution, were determined by the sessile and pendent drop methods respectively using the ADSA-P software. Wettability studies showed that hydrophobicity of the coatings increase with the glass addition. The work of adhesion of albumin was also altered in a controlled manner by the addition of the CaO-P2O5 glass, being lower on the composite coatings than on HA. Zeta potential (ZP) results showed that composite coatings presented a higher net negative charge than HA coatings and that ZP values were also influenced by the content of the glass. This study demonstrated that the surface properties of those coatings may be modified by the addition of CaO-P2O5 glass.

  7. Processing Parameter Effects and Thermal Properties of Y2Si2O7 Nanostructured Environmental Barrier Coatings Synthesized by Solution Precursor Induction Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Darthout, Émilien; Laduye, Guillaume; Gitzhofer, François

    2016-10-01

    The solution precursor plasma spray process, in which a solution of metal salts is axially injected into an induction thermal plasma, is suitable for deposition of nanostructured environmental barrier coatings. The effects of main processing parameters, namely the solution precursor concentration, spraying distance, reactor pressure, and atomization gas flow rate, have been analyzed using D-optimal design of experiments regarding the deposition rate and coating porosity responses. Among these four parameters, the solution precursor concentration had the greatest influent on the coating structure, followed by the spraying distance and reactor pressure, and finally the atomization gas flow rate with a small contribution. It is pointed out that the species that impact on the substrate are agglomerates of nanoparticles. The equivalent thermal conductivity of selected coatings was computed from experimental temperature evolution curves obtained by laser flash thermal diffusivity analysis, using two methods: a multilayer finite-element model with optimization, and a multilayer thermal diffusion model. The results of the two models agree, with coatings exhibiting low thermal conductivity between 0.7 and 1 W/(m K) at 800 °C.

  8. Effects of silver and group II fluoride solid lubricant additions to plasma-sprayed chromium carbide coatings for foil gas bearings to 650 C

    NASA Technical Reports Server (NTRS)

    Wagner, R. C.; Sliney, Harold E.

    1986-01-01

    A new self-lubricating coating composition of nickel aluminide-bonded chromium carbide formulated with silver and Group II fluorides was developed in a research program on high temperature solid lubricants. One of the proposed applications for this new coating composition is as a wide temperature spectrum solid lubricant for complaint foil gas bearings. Friction and wear properties were obtained using a foil gas bearing start-stop apparatus at temperatures from 25 to 650 C. The journals were Inconel 748. Some were coated with the plasma sprayed experimental coating, others with unmodified nickel aluminide/chromium carbide as a baseline for comparison. The additional components were provided to assist in achieving low friction over the temperature range of interest. Uncoated, preoxidized Inconel X-750 foil bearings were operated against these surfaces. The foils were subjected to repeated start/stop cycles under a 14-kPa (2-Psi) bearing unit loading. Sliding contact occurred during lift-off and coastdown at surface velocities less than 6 m/s (3000 rPm). Testing continued until 9000 start/stop cycles were accumulated or until a rise in starting torque indicated the journal/bearing had failed. Comparison in coating performance as well as discussions of their properties and methods of application are given.

  9. Characterization and durability testing of plasma-sprayed zirconia-yttria and hafnia-yttria thermal barrier coatings. Part 2: Effect of spray parameters on the performance of several hafnia-yttria and zirconia-yttria coatings

    NASA Technical Reports Server (NTRS)

    Miller, Robert A.; Leissler, George W.

    1993-01-01

    This is the second of two reports which discuss initial experiments on thermal barrier coatings prepared and tested in newly upgraded plasma spray and burner rig test facilities at LeRC. The first report, part 1, describes experiments designed to establish the spray parameters for the baseline zirconia-yttria coating. Coating quality was judged primarily by the response to burner rig exposure, together with a variety of other characterization approaches including thermal diffusivity measurements. That portion of the study showed that the performance of the baseline NASA coating was not strongly sensitive to processing parameters. In this second part of the study, new hafnia-yttria coatings were evaluated with respect to both baseline and alternate zirconia-yttria coatings. The hafnia-yttria and the alternate zirconia-yttria coatings were very sensitive to plasma-spray parameters in that high-quality coatings were obtained only when specific parameters were used. The reasons for this important observation are not understood.

  10. Synthesis and characterization of porous hydroxyapatite and hydroxyapatite coatings

    SciTech Connect

    Nieh, T G; Choi, B W; Jankowski, A F

    2000-10-25

    A technique is developed to construct bulk hydroxyapatite (HAp) with different cellular structures. The technique involves the initial synthesis of nanocrystalline hydroxyapatite powder from an aqueous solution using water-soluble compounds and then followed by spray drying into agglomerated granules. The granules were further cold pressed and sintered into bulks at elevated temperatures. The sintering behavior of the HAp granules was characterized and compared with those previously reported. Resulting from the fact that the starting HAp powders were extremely fine, a relatively low activation energy for sintering was obtained. In the present study, both porous and dense structures were produced by varying powder morphology and sintering parameters. Porous structures consisting of open cells were constructed. Sintered structures were characterized using scanning electron microscopy and x-ray tomography. In the present paper, hydroxyapatite coatings produced by magnetron sputtering on silicon and titanium substrates will also be presented. The mechanical properties of the coatings were measured using nanoindentation techniques and microstructures examined using transmission electron microscopy.

  11. Correlation of Microstructures and Tribological Properties of Ferrous Coatings Deposited by Atmospheric Plasma Spraying on Al-Si Cast Alloy Substrate

    NASA Astrophysics Data System (ADS)

    Vencl, Aleksandar; Mrdak, Mihailo; Banjac, Miloš

    2009-02-01

    The microstructure and tribological properties of ferrous coatings applicable to cylinder bores were investigated in this study. Two kinds of ferrous powders were sprayed on Al-Si cast alloy (EN AlSi10Mg) substrate by atmospheric plasma spraying. Microstructural analysis showed that various Fe oxides were formed in the coatings. The presence of pores, unmelted particles, and Fe precipitates was also noticed. The pin-on-ring tribometer was used to carry out tribological tests under lubricated sliding conditions: sliding speed of 0.5 m/s, sliding distance of 5000 m, and normal load of 450 N. High porosity and the presence of larger and irregularly shaped pores as well as the amount of oxides were the controlling factors for the crack initiations and, consequently, the wear rate. Tribological properties of the coatings were compared with gray cast iron as a standard material for cylinder blocks and showed that, for the investigated conditions, both coatings could be an adequate substitution.

  12. Hydroxyapatite coatings on Ti produced by hot isostatic pressing.

    PubMed

    Herø, H; Wie, H; Jørgensen, R B; Ruyter, I E

    1994-03-01

    Plasma spraying is a technique currently used in the production of HA-coated titanium implants. These coatings have been shown to be porous; they dissolve and have a weak bond to the substrate. The long-term interface strength has been questioned in particular. The aim of the present work was to produce HA coatings without the shortcomings of those produced by plasma spraying. Hot isostatic pressing (HIP) at 850 degrees C and 1000 bar with no holding time was applied for this purpose. Initially, the HA powder was mixed with water and air sprayed on the Ti substrate. The Ti specimens were then cold-pressed, enclosed by a protective Pt foil, and encapsulated in an evacuated glass ampulla. Subsequent to HIP, the glass and the Pt foil were removed. These coatings were denser than those produced by plasma spraying. The bonding was measured to be > 62 MPa, which is considered to be satisfactory. The structure of the coating was checked by X-ray diffraction and IR spectroscopy, and was found to correspond to that of HA. Some cracks were observed in the coating running predominantly vertical to the surface. Whether these are acceptable has to be verified by in vivo experiments.

  13. Study of metallic powder behavior in very low pressure plasma spraying (VLPPS) — Application to the manufacturing of titanium–aluminum coatings

    SciTech Connect

    Vautherin, B.; Planche, M.-P.; Montavon, G.; Lapostolle, F.; Quet, A.; Bianchi, L.

    2015-08-28

    In this study, metallic materials made of aluminum and titanium were manufactured implementing very low pressure plasma spraying (VLPPS). Aluminum was selected at first as a demonstrative material due to its rather low vaporization enthalpy (i.e., 381.9 kJ·mol⁻¹). Developments were then carried out with titanium which exhibits a higher vaporization enthalpy (i.e., 563.6 kJ·mol⁻¹). Optical emission spectroscopy (OES) was implemented to analyze the behavior of each solid precursor (metallic powders) when it is injected into the plasma jet under very low pressure (i.e., in the 150 Pa range). Besides, aluminum, titanium and titanium–aluminum coatings were deposited in the same conditions implementing a stick-cathode plasma torch operated at 50 kW, maximum power. Coating phase compositions were identified by X-Ray Diffraction (XRD). Coating elementary compositions were quantified by Glow Discharge Optical Emission Spectroscopy (GDOES) and Energy Dispersive Spectroscopy (EDS) analyses. The coating structures were observed by Scanning Electron Microscopy (SEM). The coating void content was determined by Ultra-Small Angle X-ray Scattering (USAXS). The coatings exhibit a two-scale structure corresponding to condensed vapors (smaller scale) and solidified areas (larger scale). Titanium–aluminum sprayed coatings, with various Ti/Al atomic ratios, are constituted of three phases: metastable α-Ti, Al and metastable α₂-Ti₃Al. This latter is formed at elevated temperature in the plasma flow, before being condensed. Its rather small fraction, impeded by the rather small amount of vaporized Ti, does not allow modifying however the coating hardness.

  14. Development of a hydroxyapatite coating containing silver for the prevention of peri-prosthetic infection.

    PubMed

    Ghani, Yaser; Coathup, Melanie J; Hing, Karin A; Blunn, Gordon W

    2012-03-01

    We hypothesized that the electrochemical deposition of hydroxyapatite (EHA) can be used to incorporate silver (Ag), providing a controlled and sustained release of Ag ions at a bactericidal concentration. Six groups were investigated: electrochemical co-precipitation of HA and Ag (EHA/Ag); EHA pre-coated discs treated in AgN0(3) (EHA/AgN0(3)); plasma sprayed HA (PHA) pre-coated discs treated in AgN0(3) (PHA/AgN0(3)); EHA with 2 "layers" of Ag (EHA/Ag/2 layers); EHA coating only; and PHA coating only. Scanning electron microscopy (SEM) and energy dispersive X-ray (EDX) and X-ray diffraction (XRD) analyses quantified coating thickness, calcium/phosphorous ratio, and % atomic silver content, respectively. Inductively coupled plasma-mass spectrometry quantified the amount of Ag released in phosphate-buffered saline, and zone of inhibition tests on agar plates using a lawn of Staph aureus were quantified in each group. XRD and EDX analysis confirmed the presence of Ag in all coatings. EHA coated discs with two layers of Ag and the EHA discs soaked in AgN0(3) showed significantly higher zones of inhibition at all time points when compared with all other groups (except PHA/AgN0(3) on day 0). This study demonstrated that Ag ions can be incorporated into a HA coating using an electrochemical technique.

  15. Suspension thermal spraying of hydroxyapatite: microstructure and in vitro behaviour.

    PubMed

    Bolelli, Giovanni; Bellucci, Devis; Cannillo, Valeria; Lusvarghi, Luca; Sola, Antonella; Stiegler, Nico; Müller, Philipp; Killinger, Andreas; Gadow, Rainer; Altomare, Lina; De Nardo, Luigi

    2014-01-01

    In cementless fixation of metallic prostheses, bony ingrowth onto the implant surface is often promoted by osteoconductive plasma-sprayed hydroxyapatite coatings. The present work explores the use of the innovative High Velocity Suspension Flame Spraying (HVSFS) process to coat Ti substrates with thin homogeneous hydroxyapatite coatings. The HVSFS hydroxyapatite coatings studied were dense, 27-37μm thick, with some transverse microcracks. Lamellae were sintered together and nearly unidentifiable, unlike conventional plasma-sprayed hydroxyapatite. Crystallinities of 10%-70% were obtained, depending on the deposition parameters and the use of a TiO2 bond coat. The average hardness of layers with low (<24%) and high (70%) crystallinity was ≈3.5GPa and ≈4.5GPa respectively. The distributions of hardness values, all characterised by Weibull modulus in the 5-7 range, were narrower than that of conventional plasma-sprayed hydroxyapatite, with a Weibull modulus of ≈3.3. During soaking in simulated body fluid, glassy coatings were progressively resorbed and replaced by a new, precipitated hydroxyapatite layer, whereas coatings with 70% crystallinity were stable up to 14days of immersion. The interpretation of the precipitation behaviour was also assisted by surface charge assessments, performed through Z-potential measurements. During in vitro tests, HA coatings showed no cytotoxicity towards the SAOS-2 osteoblast cell line, and surface cell proliferation was comparable with proliferation on reference polystyrene culture plates.

  16. Dual-Layer Oxidation-Protective Plasma-Sprayed SiC-ZrB2/Al2O3-Carbon Nanotube Coating on Graphite

    NASA Astrophysics Data System (ADS)

    Ariharan, S.; Sengupta, Pradyut; Nisar, Ambreen; Agnihotri, Ankur; Balaji, N.; Aruna, S. T.; Balani, Kantesh

    2016-12-01

    Graphite is used in high-temperature gas-cooled reactors because of its outstanding irradiation performance and corrosion resistance. To restrict its high-temperature (>873 K) oxidation, atmospheric-plasma-sprayed SiC-ZrB2-Al2O3-carbon nanotube (CNT) dual-layer coating was deposited on graphite substrate in this work. The effect of each layer was isolated by processing each component of the coating via spark plasma sintering followed by isothermal kinetic studies. Based on isothermal analysis and the presence of high residual thermal stress in the oxide scale, degradation appeared to be more severe in composites reinforced with CNTs. To avoid the complexity of analysis of composites, the high-temperature activation energy for oxidation was calculated for the single-phase materials only, yielding values of 11.8, 20.5, 43.5, and 4.5 kJ/mol for graphite, SiC, ZrB2, and CNT, respectively, with increased thermal stability for ZrB2 and SiC. These results were then used to evaluate the oxidation rate for the composites analytically. This study has broad implications for wider use of dual-layer (SiC-ZrB2/Al2O3) coatings for protecting graphite crucibles even at temperatures above 1073 K.

  17. Dual-Layer Oxidation-Protective Plasma-Sprayed SiC-ZrB2/Al2O3-Carbon Nanotube Coating on Graphite

    NASA Astrophysics Data System (ADS)

    Ariharan, S.; Sengupta, Pradyut; Nisar, Ambreen; Agnihotri, Ankur; Balaji, N.; Aruna, S. T.; Balani, Kantesh

    2017-02-01

    Graphite is used in high-temperature gas-cooled reactors because of its outstanding irradiation performance and corrosion resistance. To restrict its high-temperature (>873 K) oxidation, atmospheric-plasma-sprayed SiC-ZrB2-Al2O3-carbon nanotube (CNT) dual-layer coating was deposited on graphite substrate in this work. The effect of each layer was isolated by processing each component of the coating via spark plasma sintering followed by isothermal kinetic studies. Based on isothermal analysis and the presence of high residual thermal stress in the oxide scale, degradation appeared to be more severe in composites reinforced with CNTs. To avoid the complexity of analysis of composites, the high-temperature activation energy for oxidation was calculated for the single-phase materials only, yielding values of 11.8, 20.5, 43.5, and 4.5 kJ/mol for graphite, SiC, ZrB2, and CNT, respectively, with increased thermal stability for ZrB2 and SiC. These results were then used to evaluate the oxidation rate for the composites analytically. This study has broad implications for wider use of dual-layer (SiC-ZrB2/Al2O3) coatings for protecting graphite crucibles even at temperatures above 1073 K.

  18. Dose-Dependent Effects of CeO2 on Microstructure and Antibacterial Property of Plasma-Sprayed TiO2 Coatings for Orthopedic Application

    NASA Astrophysics Data System (ADS)

    Zhao, Xiaobing; Liu, Gaopeng; Zheng, Hai; Cao, Huiliang; Liu, Xuanyong

    2015-02-01

    Titanium and its alloys have been used extensively for orthopedic and dental implants. Although these devices have achieved high rates of success, two major complications may be encountered: the lack of osseointegration and the biomaterial-related infection. Accordingly, cerium oxide (CeO2)-doped titanium oxide (TiO2) materials were coated on titanium by an atmospheric plasma spraying (APS) technique. The phase structures, morphologies, and surface chemical states of the obtained coatings were characterized by x-ray diffraction, scanning electron microscopy, and x-ray photoelectron spectroscopy techniques. The in vitro antibacterial and cytocompatibility of the materials were studied with Staphylococcus aureus ( S. aureus, ATCC25923) and osteoblast precursor cell line MC3T3-E1. The results indicated that the addition of CeO2 shifts slightly the diffraction peaks of TiO2 matrix to low angles but does not change its rutile phase structure. In addition, the CeO2/TiO2 composite coatings possess dose-dependent corrosion resistance and antimicrobial properties. And doping of 10 wt.% CeO2 exhibits the highest activity against S. aureus, improved corrosion resistance, and competitive cytocompatibility, which argues a promising option for balancing the osteogenetic and antibacterial properties of titanium implants.

  19. Isothermal Oxidation Behavior of VC and Columnar Structured Thermal Barrier Coatings Deposited by Suspension Plasma Spray Technology

    NASA Astrophysics Data System (ADS)

    Li, Xiaolong; Yang, Qi; Huang, Xiao; Tang, Zhaolin

    2015-08-01

    The effects of different thermal barrier coating (TBC) top coat structures and substrate alloys on the isothermal oxidation behaviors of TBC systems were investigated at 1080 °C in lab air. The tested TBC systems consisted of two nickel-based superalloy substrates (CMSX-4 and IN738LC), a platinum aluminide bond coat and two 8YSZ top coats (vertical cracked and columnar structured). Samples with IN738LC substrate demonstrated longer isothermal oxidation lives than the counterparts with CMSX-4 substrate. Outward refractory elemental diffusion in coating systems with CMSX-4 substrate and void formation at the interface between thermally grown oxide and bond coat was found to be responsible for the early failure of TBCs. Columnar structured YSZ top coat seemed to provide better protection of the bond coating and substrate, marginally delaying the failure of the both coating systems with IN738LC and CMSX-4.

  20. Characterization and corrosion behavior of hydroxyapatite coatings on Ti6Al4V fabricated by electrophoretic deposition

    NASA Astrophysics Data System (ADS)

    Kwok, C. T.; Wong, P. K.; Cheng, F. T.; Man, H. C.

    2009-04-01

    In order to increase the bone bioactivity of the metallic implants, hydroxyapatite (HA) is often coated on their surface so that a real bond with the surrounding bone tissue can be formed. Plasma spraying of HA coatings is currently the only commercial process in use but long-term stability of plasma sprayed coatings could be a problem because of their high degree of porosities, poor bond strength, presence of a small amount of amorphous phase with non-stoichiometric composition, and non-uniformity. In the present study, cathodic electrophoretic deposition (EPD) has been attempted for depositing HA coatings on Ti6Al4V followed by vacuum sintering at 800 °C. Submicron HA powders with different morphologies including spherical, needle-shaped and flake-shaped were used in the EDP process to produce dense coatings. Moreover, carbon nanotubes (CNTs) were also used to reinforce the HA coating for enhancing its hardness. The surface morphology, compositions and microstructure of the HA coated Ti6Al4V were investigated by electron microscopy, energy-dispersive X-ray spectroscopy and X-ray diffractometry, respectively. Electrochemical corrosion behavior of the HA coatings in Hanks' solution at 37 °C was investigated by means of open-circuit potential measurement and cyclic potentiodynamic polarization tests. Surface hardness, adhesion strength and bone bioactivity of the coatings were also studied. All HA coated specimens had a thickness of about 10 μm and free of cracks, with corrosion resistance higher than that of the substrate and adhesion strength higher than that of plasma sprayed coating. The enhanced properties could be attributed to the use of submicron-sized HA particles in the low-temperature EDP process. Among the three types of HA powder, spherical powder yielded the densest coating whereas the flake-shaped powder yielded the most porous coatings. Compared with monolithic HA coating, the CNT-reinforced HA coating markedly increased the coating hardness

  1. Mode I, Mode II, and Mixed-Mode Fracture of Plasma-sprayed Thermal Barrier Coatings at Ambient and Elevated Temperatures

    NASA Technical Reports Server (NTRS)

    Choi, Sung R.; Zhu, Dongming; Miller, Robert A.

    2003-01-01

    The mixed-mode fracture behavior of plasma-sprayed ZrO2-8 wt% Y2O3 thermal barrier coatings was determined in air at 25 and 1316 C in asymmetric four-point flexure with single edge v-notched beam (SEVNB) test specimens. The mode I fracture toughness was found to be K(sub Ic) = 1.15 plus or minus 0.07 and 0.98 plus or minus 0.13 MPa the square root of m, respectively, at 25 and 1316 C. The respective mode II fracture toughness values were K(sub IIc) = 0.73 plus or minus 0.10 and 0.65 plus or minus 0.04 MPa the square root of m. Hence, there was an insignificant difference in either K(sub Ic or K(sub IIc) between 25 and 1316 C for the coating material, whereas there was a noticeable distinction between K(sub Ic) and K(sub IIc), resulting in K(sub IIc) per K(sub Ic) = 0.65 at both temperatures. The empirical mixed-mode fracture criterion best described the coatings' mixed-mode fracture behavior among the four mixed-mode fracture theories considered. The angle of crack propagation was in reasonable agreement with the minimum strain energy density criterion. The effect of the directionality of the coating material in on K(sub Ic) was observed to be insignificant, while its sintering effect at 1316 C on K(sub Ic) was significant.

  2. Synthesis of functional oxides through plasma spraying

    NASA Astrophysics Data System (ADS)

    Guo, Xianzhong

    Thermal spray coatings have become an important part of modern industry, offering customized surface properties for a variety of industrial applications, e.g. thermal barrier coatings, wear resistant coatings, erosion resistant coatings and functional coatings. Although the usage of thermal spray coatings has increased dramatically, the scientific research of these coatings has lagged behind. Good understanding of thermal spray processes can provide the optimistic combination of operation parameters to obtain high quality of coating, improve service life of the product, and lower cost of the system. The research presented in this dissertation focuses on the synthesis of functional oxide coatings through plasma spraying techniques. The materials studied in this research are: yttrium aluminum garnet (YAG) which can be the thermal barrier coating and environmental barrier coating; doped YAG as phosphor; yttrium iron garnet (YIG) applied in telecommunication and data storage; aluminum substituted YIG for biomedical applications; and zirconium substituted yttrium titanate pyrochlore in developing solid oxide fuel cells (SOFCs). The synthesis processes, phase formation, microstructure, and physical properties of above materials have been investigated in a comprehensive and integrated way. The precursor powders or solutions were prepared via different chemical routes. The experiments suggest that formation of phase-pure oxides occurs through different phase evolution pathways and depending on the reaction conditions. Chemically derived precursors and/or powders were used as feedstock in plasma spray to form functional oxide coatings. Due to its rapid heating and cooling features, plasma spraying techniques provide a novel opportunity for functional oxides to transfer from amorphous into crystallized structure at a relatively low temperature in a single step. The properties of assprayed and post-heated coatings strongly depend on their microstructure and phase content.

  3. Study of the microstructure of plasma sprayed coatings obtained from Al{sub 2}O{sub 3}–13TiO{sub 2} nanostructured and conventional powders

    SciTech Connect

    Góral, A.; Żórawski, W.; Lityńska-Dobrzyńska, L.

    2014-10-15

    The microstructure of coatings obtained from nanostructured or conventional Al{sub 2}O{sub 3}–13TiO{sub 2} powders and deposited by plasma spraying technique on low-carbon steel was examined by transmission electron microscopy techniques. The dominating phase in both coatings was γ-Al{sub 2}O{sub 3} phase. It has been observed that the grains of γ-Al{sub 2}O{sub 3} grew in various shapes and sizes, that are particularly visible in the case of coating sprayed from nanostructured powder. The coatings obtained from the fully melted conventional powders exhibited a typical lamellar microstructure, into which the strips of TiO{sub 2} phase were extended. The microstructure of coatings produced from agglomerates of nanostructured particles also revealed the regions consisting of partially melted α-Al{sub 2}O{sub 3} powders surrounded by the net-like structure formed from fully melted oxides that improved the coating properties. Along with the observed morphology diversity some changes in the chemical composition on the cross sections of obtained coatings have been also noticed. - Highlights: • Plasma sprayed Al{sub 2}O{sub 3}–13TiO{sub 2} coatings reveal diversity of microstructure. • Microstructure of conventional coating was formed from fully melted crushed powders. • Nanostructured coating contains completely and partially melted initial agglomerates.

  4. Wear studies on plasma-sprayed Al2O3 and 8mole% of Yttrium-stabilized ZrO2 composite coating on biomedical Ti-6Al-4V alloy for orthopedic joint application.

    PubMed

    Ganapathy, Perumal; Manivasagam, Geetha; Rajamanickam, Asokamani; Natarajan, Alagumurthi

    2015-01-01

    This paper presents the wear characteristics of the composite ceramic coating made with Al2O3-40wt%8YSZ on the biomedical grade Ti-6Al-4V alloy (grade 5) used for total joint prosthetic components, with the aim of improving their tribological behavior. The coatings were deposited using a plasma spraying technique, and optimization of plasma parameters was performed using response surface methodology to obtain dense coating. The tribological behaviors of the coated and uncoated substrates were evaluated using a ball-on-plate sliding wear tester at 37°C in simulated body-fluid conditions. The microstructure of both the titanium alloy and coated specimen were examined using an optical microscope and scanning electron microscope. The hardness of the plasma-sprayed alumina-zirconia composite coatings was 2.5 times higher than that of the Ti-6Al-4V alloy, while the wear rate of Ti-6Al-4V alloy was 253 times higher than that of the composite-coated Ti-6Al-4V alloy. The superior wear resistance of the alumina-zirconia coated alloy is attributed to its enhanced hardness and intersplat bonding strength. Wear-track examination showed that the predominant wear mechanism of Ti-6Al-4V alloy was abrasive and adhesive wear, whereas, in the case of alumina-zirconia composite coated alloy, the wear was dominated by microchipping and microcracking.

  5. Wear studies on plasma-sprayed Al2O3 and 8mole% of Yttrium-stabilized ZrO2 composite coating on biomedical Ti-6Al-4V alloy for orthopedic joint application

    PubMed Central

    Ganapathy, Perumal; Manivasagam, Geetha; Rajamanickam, Asokamani; Natarajan, Alagumurthi

    2015-01-01

    This paper presents the wear characteristics of the composite ceramic coating made with Al2O3-40wt%8YSZ on the biomedical grade Ti-6Al-4V alloy (grade 5) used for total joint prosthetic components, with the aim of improving their tribological behavior. The coatings were deposited using a plasma spraying technique, and optimization of plasma parameters was performed using response surface methodology to obtain dense coating. The tribological behaviors of the coated and uncoated substrates were evaluated using a ball-on-plate sliding wear tester at 37°C in simulated body-fluid conditions. The microstructure of both the titanium alloy and coated specimen were examined using an optical microscope and scanning electron microscope. The hardness of the plasma-sprayed alumina–zirconia composite coatings was 2.5 times higher than that of the Ti-6Al-4V alloy, while the wear rate of Ti-6Al-4V alloy was 253 times higher than that of the composite-coated Ti-6Al-4V alloy. The superior wear resistance of the alumina–zirconia coated alloy is attributed to its enhanced hardness and intersplat bonding strength. Wear-track examination showed that the predominant wear mechanism of Ti-6Al-4V alloy was abrasive and adhesive wear, whereas, in the case of alumina–zirconia composite coated alloy, the wear was dominated by microchipping and microcracking. PMID:26491323

  6. High power plasma spraying of oxide ceramics

    SciTech Connect

    Lugscheider, E.; Jungklaus, H.; Schwier, G.; Mathesius, H.; Heinrich, P.

    1995-12-31

    New developed high power plasma spray (HPPS) systems offer opportunities for generating both high thermal as well as high kinetic energy transfer to the powder particles. The operation level can be elevated up to 250 kW for continuous processing. PLCs and mass flow controls support high power processing under production conditions. The process is designed for applying large quantities even of high melt materials, such as oxide ceramics. High power plasma processing may result in enhanced coating characteristics. The work in this paper shows first conclusions for processing commercial powders such as alumina, alumina-titania, chromia and a recently developed multicomponent oxide with a HPPS system. Particle velocities were measured after optimizing spraying parameters. Coatings were evaluated by optical microscopy (microstructure and porosity), microhardness and pin-on-disc abrasive wear tests. Powder types and sizes as well as the systems configuration are considered for a general discussion of the capability and limitation in high power plasma spraying.

  7. Influence of substrate metal alloy type on the properties of hydroxyapatite coatings deposited using a novel ambient temperature deposition technique.

    PubMed

    Barry, J N; Cowley, A; McNally, P J; Dowling, D P

    2014-03-01

    Hydroxyapatite (HA) coatings are applied widely to enhance the level of osteointegration onto orthopedic implants. Atmospheric plasma spray (APS) is typically used for the deposition of these coatings; however, HA crystalline changes regularly occur during this high-thermal process. This article reports on the evaluation of a novel low-temperature (<47°C) HA deposition technique, called CoBlast, for the application of crystalline HA coatings. To-date, reports on the CoBlast technique have been limited to titanium alloy substrates. This study addresses the suitability of the CoBlast technique for the deposition of HA coatings on a number of alternative metal alloys utilized in the fabrication of orthopedic devices. In addition to titanium grade 5, both cobalt chromium and stainless steel 316 were investigated. In this study, HA coatings were deposited using both the CoBlast and the plasma sprayed techniques, and the resultant HA coating and substrate properties were evaluated and compared. The CoBlast-deposited HA coatings were found to present similar surface morphologies, interfacial properties, and composition irrespective of the substrate alloy type. Coating thickness however displayed some variation with the substrate alloy, ranging from 2.0 to 3.0 μm. This perhaps is associated with the electronegativity of the metal alloys. The APS-treated samples exhibited evidence of both coating, and significantly, substrate phase alterations for two metal alloys; titanium grade 5 and cobalt chrome. Conversely, the CoBlast-processed samples exhibited no phase changes in the substrates after depositions. The APS alterations were attributed to the brief, but high-intensity temperatures experienced during processing.

  8. Nickel-chromium plasma spray coatings: A way to enhance degradation resistance of boiler tube steels in boiler environment

    SciTech Connect

    Sidhu, B.S.; Prakash, S.

    2006-03-15

    Boiler tube steels, namely low carbon steel ASTM-SA210-Grade A1 (GrA1), 1Cr-0.5Mo steel ASTM-SA213-T-11 (T11), and 2.25Cr-1Mo steel ASTM-SA213-T-22 (T22), were used as substrate steels. Ni-22Cr-10AI-1Y powder was sprayed as a bond coat 150 {mu}m thick before a 200 {mu}m final coating of Ni-20Cr was applied. Coatings were characterized prior to testing in the environment of a coal fired boiler. The uncoated and coated steels were inserted in the platen superheater zone of a coal fired boiler at around 755{sup o}C for 10 cycles, each 100 h. Coated steels showed lower degradation (erosion-corrosion) rate than uncoated steels showed. The lowest rate was observed in the case of Ni-20Cr coated T11 steel. Among the uncoated steels, the observed rate of degradation was the lowest for the T22 steel.

  9. Arthrodesis Rate and Patient Reported Outcomes After Anterior Lumbar Interbody Fusion Utilizing a Plasma-Sprayed Titanium Coated PEEK Interbody Implant: A Retrospective, Observational Analysis

    PubMed Central

    Bergen, Sophea R.; Staples, Miranda; Liang, Kevin; Raiszadeh, Ramin

    2017-01-01

    Background Anterior lumbar interbody fusion (ALIF) is utilized in symptomatic spinal disc destabilization due to degenerative lumbar disc disease, isthmic and degenerative spondylolisthesis, internal disc disruption, or pseudarthrosis after non-operative treatments fail. The addition of a plasma-sprayed titanium coating (PTC) to polyether ether ketone spacers (PEEK) may reduce the rate of implant subsidence or non-union secondary to poor osseous-integration of non-coated PEEK or metal interbody systems. Methods A retrospective, non-randomized, single-center chart review, evaluated the post-surgical follow-up data of patients receiving a PTC PEEK implant during single or multi-level ALIF procedures to determine the clinical efficacy and rate of arthrodesis after utilization of a coated spacer. Standard roentgenographs or computed tomography were used to identify successful arthrodesis following the ALIF procedure and longitudinal clinical improvements were determined by scores on the Visual Analog Scale (VAS) for low back and leg pain. Results Forty-four subjects (48% male, mean=53 years) were included in this chart review. Follow-up radiology demonstrated radiographic union with bridging bone formation across the interbody space for 42/44 (96%) individuals with solid arthrodesis occurring at an average of 7.3 ± 2.3 months. Subjects demonstrated significant improvement in VAS low back pain (4.5 ± 2.4 point improvement, p=0.0001) and VAS leg pain (4.1 ± 3.3 point improvement, p=0.0001). While there was a significant reduction in the improvement of VAS low back pain of Worker's Compensation claimants as compared to other patients (3.9 ± 2.4 vs. 5.3 ± 2.1), there was no difference in VAS low back pain or leg pain when the data was stratified by gender, age, tobacco use, comorbidities, prior surgery, fusion construct length, use of supplemental posterior instrumentation, BMI, or diagnosis. Conclusions This study provides support that the addition of a PTC coating

  10. Bacterial adhesion to bisphosphonate coated hydroxyapatite.

    PubMed

    Ganguli, A; Steward, C; Butler, S L; Philips, G J; Meikle, S T; Lloyd, A W; Grant, M H

    2005-04-01

    Staphylococcus aureus (S. aureus) is commonly associated with microbial infection of orthopaedic implants. Such infections often lead to osteomyelitis, which may result in failure of the implant due to localised bone destruction. Bacterial adhesion and subsequent colonisation of the device may occur as a consequence of contamination during surgery, or by seeding from a distant site through the blood circulation. Coating of the hydroxyapatite (HA) ceramic component of artificial hip joints with the bisphosphonates clodronate (C) and pamidronate (P) has been proposed as a means to minimise osteolysis and thereby prevent loosening of the implant. However, the effect of the bisphosphonate coating on bacterial adhesion to the HA materials must be determined before this approach can be implemented. In this study coated HA materials were incubated with the S. aureus and the number of adherent bacteria determined using the Modified Vortex Device (MVD) method. The number of bacteria adherent to the P coated HA material was significantly greater than that adherent to uncoated HA (60-fold increase) or to the C coated HA (90-fold increase). Therefore, even though earlier studies suggested that P bound to HA may improve osseointegration, the results presented would suggest that the use of this coating may be limited by the potential increased susceptibility of the coated device to infection.

  11. Automated Plasma Spray (APS) process feasibility study

    NASA Technical Reports Server (NTRS)

    Fetheroff, C. W.; Derkacs, T.; Matay, I. M.

    1981-01-01

    An automated plasma spray (APS) process was developed to apply two layer (NiCrAlY and ZrO2-12Y2O3) thermal barrier coatings to aircraft and stationary gas turbine engine blade airfoils. The APS process hardware consists of four subsystems: a mechanical positioning subsystem incorporating two interlaced six degree of freedom assemblies (one for coating deposition and one for coating thickness monitoring); a noncoherent optical metrology subsystem (for in process gaging of the coating thickness buildup at specified points on the specimen); a microprocessor based adaptive system controller (to achieve the desired overall thickness profile on the specimen); and commerical plasma spray equipment. Over fifty JT9D first stage aircraft turbine blade specimens, ten W501B utility turbine blade specimens and dozens of cylindrical specimens were coated with the APS process in preliminary checkout and evaluation studies. The best of the preliminary turbine blade specimens achieved an overall coating thickness uniformity of 53 micrometers (2.1 mils), much better than is achievable manually. Comparative evaluations of coating thickness uniformity for manually sprayed and APS coated specimens were performed. One of the preliminary turbine blade evaluation specimens was subjected to a torch test and metallographic evaluation. Some cylindrical specimens coated with the APS process survived up to 2000 cycles in subsequent burner rig testing.

  12. In vitro mechanical integrity of hydroxyapatite coated magnesium alloy.

    PubMed

    Kannan, M Bobby; Orr, Lynnley

    2011-08-01

    The mechanical integrity of resorbable implants during service, especially in load bearing orthopaedic applications, is critical. The high degradation rate of resorbable magnesium and magnesium-based implants in body fluid may potentially cause premature in-service failure. In this study, a magnesium alloy (AZ91) was potentiostatically coated with hydroxyapatite at different cathodic voltages in an attempt to enhance the mechanical integrity. The mechanical integrity of the uncoated and hydroxyapatite coated alloys was evaluated after in vitro testing of the coated samples in simulated body fluid (SBF). The uncoated alloy showed 40% loss in the mechanical strength after five days exposure to SBF. However, the hydroxyapatite coated alloy exposed to SBF showed 20% improvement in the mechanical strength as compared to that of the uncoated alloy. The alloy coated potentiostatically at -2 V performed better than the -3 V coated alloy. The cross-sectional analysis of the coatings revealed relatively uniform coating thickness for the -2 V coated alloy, whereas the -3 V coated alloy exhibited areas of uneven coating. This can be attributed to the increase in hydrogen evolution on the alloy during -3 V coating as compared to -2 V coating. The scanning electron micrographs of the in vitro tested alloy revealed that hydroxyapatite coating significantly reduced the localized corrosion of the alloy, which is critical for better in-service mechanical integrity. Thus, the study suggests that the in vitro mechanical integrity of resorbable magnesium-based alloy can be improved by potentiostatic hydroxyapatite coating.

  13. Mathematical simulation of surface heating during plasma spraying

    NASA Astrophysics Data System (ADS)

    Bogdanovich, V. I.; Giorbelidze, M. G.

    2017-02-01

    A mathematical model of temperature distribution over the flat ‘coating-substrate’ system section during plasma spraying, taking into account a plasma gun travel and coating buildup has been developed. It has been shown that the temperature value in the near-surface layer of the sprayed coating during the plasma gun passage can significantly exceed the temperature values in underlayers.

  14. Mechanical and physical properties of plasma-sprayed stabilized zirconia

    NASA Technical Reports Server (NTRS)

    Siemers, P. A.; Mehan, R. L.

    1983-01-01

    Physical and mechanical properties were determined for plasma-sprayed MgO- or Y2O3-stabilized ZrO2 thermal barrier coatings. Properties were determined for the ceramic coating in both the freestanding condition and as-bonded to a metal substrate. The properties of the NiCrAlY bond coating were also investigated.

  15. Thermal and optical characterization of the calcium phosphate biomaterial hydroxyapatite

    NASA Astrophysics Data System (ADS)

    Bento, A. C.; Almond, D. P.; Brown, S. R.; Turner, I. G.

    1996-05-01

    Thermal wave interferometry (TWI) has been used to measure the thermophysical properties of hydroxyapatite (HA) coatings, prepared by the plasma-spraying process on titanium alloy substrates. The properties measured were thermal diffusivity, thermal conductivity, thermal effusivity, and volumetric heat capacity and the optical absorption coefficient. The thermal conductivity obtained was found to be of similar magnitude to that of human tooth enamel. The results presented confirm the usefulness of TWI as a nondestructive technique for the characterization of plasma-sprayed HA coatings.

  16. Creep of plasma sprayed zirconia

    NASA Technical Reports Server (NTRS)

    Firestone, R. F.; Logan, W. R.; Adams, J. W.

    1982-01-01

    Specimens of plasma-sprayed zirconia thermal barrier coatings with three different porosities and different initial particle sizes were deformed in compression at initial loads of 1000, 2000, and 3500 psi and temperatures of 1100 C, 1250 C, and 1400 C. The coatings were stabilized with lime, magnesia, and two different concentrations of yttria. Creep began as soon as the load was applied and continued at a constantly decreasing rate until the load was removed. Temperature and stabilization had a pronounced effect on creep rate. The creep rate for 20% Y2O3-80% ZrO2 was 1/3 to 1/2 that of 8% Y2O3-92% ZrO2. Both magnesia and calcia stabilized ZrO2 crept at a rate 5 to 10 times that of the 20% Y2O3 material. A near proportionality between creep rate and applied stress was observed. The rate controlling process appeared to be thermally activated, with an activation energy of approximately 100 cal/gm mole K. Creep deformation was due to cracking and particle sliding.

  17. Electrophoretic deposition of composite hydroxyapatite-chitosan coatings

    SciTech Connect

    Pang Xin; Zhitomirsky, Igor . E-mail: zhitom@mcmaster.ca

    2007-04-15

    Cathodic electrophoretic deposition has been utilized for the fabrication of composite hydroxyapatite-chitosan coatings on 316L stainless steel substrates. The addition of chitosan to the hydroxyapatite suspensions promoted the electrophoretic deposition of the hydroxyapatite nanoparticles and resulted in the formation of composite coatings. The obtained coatings were investigated by X-ray diffraction, thermogravimetric and differential thermal analysis, scanning and transmission electron microscopy, potentiodynamic polarization measurements, and electrochemical impedance spectroscopy. It was shown that the deposit composition can be changed by a variation of the chitosan or hydroxyapatite concentration in the solutions. Experimental conditions were developed for the fabrication of hydroxyapatite-chitosan nanocomposites containing 40.9-89.8 wt.% hydroxyapatite. The method enabled the formation of adherent and uniform coatings of thicknesses up to 60 {mu}m. X-ray studies revealed that the preferred orientation of the hydroxyapatite nanoparticles in the chitosan matrix increases with decreasing hydroxyapatite content in the composite coatings. The obtained coatings provided the corrosion protection for the 316L stainless steel substrates00.

  18. Plasma spraying with wire feedstock

    SciTech Connect

    Scholl, M.

    1994-12-31

    Plasma spraying has been limited to using powder feedstocks for a number of reasons. One limitation has been the low energy output of conventional plasma guns. The advent of high energy plasma spraying (HEPS) devices and the associated technology has effectively removed this functional limitation. With HEPS, the combination of high gas velocities and high thermal plasma temperatures coupled with a large exit gas volume enables wire and rod feedstocks to be effectively utilized. Rather than a bulk melting mechanism, a model based on ablation phenomena is considered. The paper examines an analysis of melting phenomena and presents a simple model for molten droplet formation for plasma spraying using wire feedstocks.

  19. Vacuum Plasma Spraying Replaces Electrodeposition

    NASA Technical Reports Server (NTRS)

    Holmes, Richard R.; Power, Chris; Burns, David H.; Daniel, Ron; Mckechnie, Timothy N.

    1992-01-01

    Vacuum plasma spraying used to fabricate large parts with complicated contours and inner structures, without uninspectable welds. Reduces time, and expense of fabrication. Wall of combustion chamber built up inside of outer nickel-alloy jacket by plasma spraying. Particles of metal sprayed partially melted in plasma gun and thrown at supersonic speed toward deposition surface. Vacuum plasma-spray produces stronger bond between the grooves and covering layer completing channels and wall of combustion chamber. In tests, bond withstood pressure of 20 kpsi, three times allowable limit by old method.

  20. Processing and Characterization of Functionally Graded Hydroxyapatite Coatings for Biomedical Implants

    NASA Astrophysics Data System (ADS)

    Bai, Xiao

    Hydroxyapatite [Ca10(PO4)6(OH) 2, HA] has been widely applied as a coating on various biomedical bone/dental implants to improve biocompatibility and bioactivity. It has been observed that primary reasons leading to implantation failure of commercial HA coated implants processed by plasma spraying are the poor mechanical properties of coatings and infections accompanied by implantation. It has been also reported an ideal coating should be able to stimulate new bone growth at the initial stage of implantation and stay stable both mechanically and chemically thereafter. This research has investigated a functionally graded hydroxyapatite (FGHA) coating that is capable of improving the stability of implants, facilitating recovery, and preventing infections after implantation. A series of FGHA coatings with incorporated Ag 0 ˜ 13.53 wt. % has been deposited onto Ti substrate using ion beam assisted deposition (IBAD) with in-situ heat treatment. The compositional, microstructural, mechanical, and biological properties of coatings have been analyzed via various tests. The relationship among processing parameters, coating properties and biological behaviors has been established and the processing parameters for processing FGHA coatings with/without incorporated Ag have been optimized. Microstructure observations of coating cross section via transmission electron microscopy (TEM) and scanning transmission electron microscopy (STEM) for set temperature coatings deposited at 450°C ˜ 750°C reveals that in-situ substrate temperature is the primary factor controlling the crystallinity of the coatings. The microstructure observation of cross section via TEM/STEM for both FGHA coatings with/without incorporated Ag has shown that coatings are dense and have a gradually decreased crystallinity from substrate/coating interface to top surface. In particular, the interface has an atomically intermixed structure; the region near the interface has a columnar grain structure whereas

  1. Characterization of plasma sprayed and explosively consolidated simulated lunar soil

    SciTech Connect

    Powell, S.J.; Inal, O.T.; Smith, M.F.

    1997-06-01

    Two methods for the use of lunar materials for the construction of shelters on the Moon are being proposed: explosive consolidation of the soil into structural components and plasma spraying of the soil to join components. The plasma-sprayed coating would also provide protection from the intense radiation. In this work, a mare simulant was plasma-sprayed onto a stainless steel substrate. Deposition of a 0.020 inch coating using power inputs of 23, 25, 27 and 29 kW were compared. Hardness of the coatings increased with each increase of power to the system, while porosity at the interface decreased. All coatings exhibited good adhesion. Simultaneously, an explosively consolidated sample was similarly characterized to afford a comparison of structural features associated with each mode of proposed use.

  2. Hydroxyapatite/poly(epsilon-caprolactone) double coating on magnesium for enhanced corrosion resistance and coating flexibility.

    PubMed

    Jo, Ji-Hoon; Li, Yuanlong; Kim, Sae-Mi; Kim, Hyoun-Ee; Koh, Young-Hag

    2013-11-01

    Hydroxyapatite was deposited on pure magnesium (Mg) with a flexible poly(ε-caprolactone) interlayer to reduce the corrosion rate of Mg and enhance coating flexibility. The poly(ε-caprolactone) interlayer was uniformly coated on Mg by a spraying method, followed by hydroxyapatite deposition on the poly(ε-caprolactone) using an aerosol deposition method. In scanning electron microscopy observations, inorganic/organic composite-like structure was observed between the hydroxyapatite and poly(ε-caprolactone) layers, resulting from the collisions of hydroxyapatite particles into the poly(ε-caprolactone) matrix at the initial stage of the aerosol deposition. The corrosion resistance of the coated Mg was examined using potentiodynamic polarization tests. The hydroxyapatite/poly(ε-caprolactone) double coating remarkably improved the corrosion resistance of Mg in Hank's solution. In the in vitro cell tests, the coated Mg showed better cell adhesion compared with the bare Mg due to the reduced corrosion rate and enhanced biocompatibility. The stability and flexibility of hydroxyapatite/poly(ε-caprolactone) double coating was investigated by scanning electron microscopy inspections after the coated Mg was deformed. The hydroxyapatite coating on the poly(ε-caprolactone) interlayer revealed enhanced coating stability and flexibility without cracking or delamination during bending and stretching compared with the hydroxyapatite single coating. These results demonstrated that the hydroxyapatite/poly(ε-caprolactone) double coating significantly improved the surface corrosion resistance of Mg and enhanced coating flexibility for use of Mg as a biodegradable implant.

  3. High-temperature tribological properties of NiCoCrAlY-WSe2-BaF2·CaF2 solid lubricant coatings prepared by plasma spraying

    NASA Astrophysics Data System (ADS)

    Chen, X. H.; Yuan, X. J.; Xia, J.; Yu, Z. H.

    2015-12-01

    In this paper, NiCoCrAlY-WSe2-BaF2·CaF2 solid lubricant coatings were produced on a substrate by plasma spray and investigated at the high temperature, such as 500 °C and 800 °C. The structure of the coatings was characterized using XRD pattern and scanning electron microscopy. The TC1 (83wt% NiCoCrAlY) coating has a low friction coefficient at 500C, where the WSe2 is a good solid lubricant. The TC2 (65wt% NiCoCrAlY) coating has the low friction coefficient (0.279) at 800°C, due to the formation of BaCrO4 on the surfaces. As a result, the TC2 coating has the optimal tribological property in the wide temperature.

  4. Kinetics of hydrothermal crystallization under saturated steam pressure and the self-healing effect by nanocrystallite for hydroxyapatite coatings.

    PubMed

    Yang, Chung-Wei; Lui, Truan-Sheng

    2009-09-01

    Hydroxyapatite coatings (HACs) with a low crystalline state were prepared using the plasma spraying process followed by hermetic autoclaving hydrothermal treatment at 100, 150 and 200 degrees C. Experimental evidence confirmed that the HACs became significantly crystallized and the content of amorphous calcium phosphate decreased by performing the autoclaving hydrothermal treatment in an ambient saturated steam pressure system. The obvious chemisorbed hydroxy groups (OH) peak in the X-ray photoelectron spectra detected from the hydrothermally crystallized HAC specimens means that the hydroxyl-deficient state of plasma-sprayed HACs is significantly improved by the abundant replenished OH groups. The HA nanocrystallite observed from scanning electron microscopy and transmission electron microscopy images within hydrothermally treated HACs is the result of nucleation and grain growth through the replenishment of OH groups into the hydroxyl-deficient HA crystal structure. The microstructural self-healing effect is a result of reduction in defects (pores, microcracks and lamellar boundaries) due to new-growth HA nanocrystallite. According to the systematic derivation of the Arrhenius equation, the HA crystallization is a second-order Arrhenius reaction kinetics. Besides the effects of heating temperature and an atmosphere with abundant water molecules, the saturated steam pressure is a crucial factor which significantly improves the crystallization rate constant and further reduces the activation energy for the hydrothermal HA crystallization.

  5. Characterization and durability testing of plasma-sprayed zirconia-yttria and hafnia-yttria thermal barrier coatings. Part 1: Effect of spray parameters on the performance of several lots of partially stabilized zirconia-yttria powder

    NASA Technical Reports Server (NTRS)

    Miller, Robert A.; Leissler, George W.; Jobe, J. Marcus

    1993-01-01

    Initial experiments conducted on thermal barrier coatings prepared in the newly upgraded research plasma spray facility and the burner rig test facilities are discussed. Part 1 discusses experiments which establish the spray parameters for three baseline zirconia-yttria coatings. The quality of five similar coating lots was judged primarily by their response to burner rig exposure supplemented by data from other sources such as specimen characterizations and thermal diffusivity measurements. After allowing for burner rig variability, although there appears to be an optimum density (i.e., optimum microstructure) for maximum burner rig life, the distribution tends to be rather broad about the maximum. In Part 2, new hafnia-yttria-based coatings were evaluated against both baseline and alternate zirconia-yttria coatings. The hafnia-yttria coatings and the zirconia-yttria coatings that were prepared by an alternate powder vendor were very sensitive to plasma spray parameters, in that high-quality coatings were only obtained when certain parameters were employed. The reasons for this important observation are not understood. Also not understood is that the first of two replicate specimens sprayed for Part 1 consistently performed better than the second specimen. Subsequent experiments did not display this spray order affect, possibly because a chiller was installed in the torch cooling water circuit. Also, large changes in coating density were observed after switching to a new lot of electrodes. Analyses of these findings were made possible, in part, because of the development of a sensitive density measurement technique described herein in detail. The measured thermal diffusivities did not display the expected strong relationship with porosity. This surprising result was believed to have been caused by increased microcracking of the denser coatings on the stainless steel substrates.

  6. Effect of collagen on the mechanical properties of hydroxyapatite coatings.

    PubMed

    Ou, Keng-Liang; Chung, Ren-Jei; Tsai, Fu-Yi; Liang, Pei-Yu; Huang, Shih-Wei; Chang, Shou-Yi

    2011-05-01

    In this study, the mechanical properties of bioactive coatings on Ti6Al4V substrates were investigated using instrumented nanoindentation. The aim was to observe the differences in the mechanical properties before and after immersion in collagen solution. The hydroxyapatite coatings were prepared through two processes: self-assembly in simulated body fluid and a hydrothermal method. Sintered hydroxyapatite disks were used as controls. The test samples were then incubated in a dilute collagen solution for 24 hours to produce composite coatings. The materials were investigated using XRD, SEM and nanoindentation. The results showed that the grain sizes of the hydroxyapatite coatings formed using two processes were 1 μm and 10 μm, respectively. The Young's modulus of the pure hydroxyapatite, the disk and the coatings, was 3.6 GPa. After collagen incubation treatment, the composites had a Young's modulus of 7.5 GPa. The results also showed that the strengthening phenomena of collagen were more obvious for homogeneous and small-grain hydroxyapatite coatings. These results suggest that there are similarities between these HAp/collagen composited and natural composite materials, such as teeth and bones.

  7. Current problems in plasma spray processing

    SciTech Connect

    Berndt, C.C.; Brindley, W.; Goland, A.N.; Herman, H.; Houck, D.L.; Jones, K.; Miller, R.A.; Neiser, R.; Riggs, W.; Sampath, S.; Smith, M.; Spanne, P. . Thermal Spray Lab.)

    1991-01-01

    This detailed report summarizes 8 contributions from a thermal spray conference that was held in late 1991 at Brookhaven National Laboratory (Upton, Long Island, NY, USA). The subject of Plasma Spray Processing'' is presented under subject headings of Plasma-particle interactions, Deposit formation dynamics, Thermal properties of thermal barrier coatings, Mechanical properties of coatings, Feed stock materials, Porosity: An integrated approach, Manufacture of intermetallic coatings, and Synchrotron x-ray microtomographic methods for thermal spray materials. Each section is intended to present a concise statement of a specific practical and/or scientific problem, then describe current work that is being performed to investigate this area, and finally to suggest areas of research that may be fertile for future activity.

  8. Current problems in plasma spray processing

    SciTech Connect

    Berndt, C.C.; Brindley, W.; Goland, A.N.; Herman, H.; Houck, D.L.; Jones, K.; Miller, R.A.; Neiser, R.; Riggs, W.; Sampath, S.; Smith, M.; Spanne, P.

    1991-12-31

    This detailed report summarizes 8 contributions from a thermal spray conference that was held in late 1991 at Brookhaven National Laboratory (Upton, Long Island, NY, USA). The subject of ``Plasma Spray Processing`` is presented under subject headings of Plasma-particle interactions, Deposit formation dynamics, Thermal properties of thermal barrier coatings, Mechanical properties of coatings, Feed stock materials, Porosity: An integrated approach, Manufacture of intermetallic coatings, and Synchrotron x-ray microtomographic methods for thermal spray materials. Each section is intended to present a concise statement of a specific practical and/or scientific problem, then describe current work that is being performed to investigate this area, and finally to suggest areas of research that may be fertile for future activity.

  9. Laser-surface-alloyed carbon nanotubes reinforced hydroxyapatite composite coatings

    SciTech Connect

    Chen Yao; Gan Cuihua; Zhang Tainua; Yu Gang; Bai Pucun; Kaplan, Alexander

    2005-06-20

    Carbon-nanotube (CNT)-reinforced hydroxyapatite composite coatings have been fabricated by laser surface alloying. Microstructural observation using high-resolution transmission electron microscopy showed that a large amount of CNTs remained with their original tubular morphology, even though some CNTs reacted with titanium element in the substrate during laser irradiation. Additionally, measurements on the elastic modulus and hardness of the composite coatings indicated that the mechanical properties were affected by the amount of CNTs in the starting precursor materials. Therefore, CNT-reinforced hydroxyapatite composite is a promising coating material for high-load-bearing metal implants.

  10. Laser-surface-alloyed carbon nanotubes reinforced hydroxyapatite composite coatings

    NASA Astrophysics Data System (ADS)

    Chen, Yao; Gan, Cuihua; Zhang, Tainua; Yu, Gang; Bai, Pucun; Kaplan, Alexander

    2005-06-01

    Carbon-nanotube (CNT)-reinforced hydroxyapatite composite coatings have been fabricated by laser surface alloying. Microstructural observation using high-resolution transmission electron microscopy showed that a large amount of CNTs remained with their original tubular morphology, even though some CNTs reacted with titanium element in the substrate during laser irradiation. Additionally, measurements on the elastic modulus and hardness of the composite coatings indicated that the mechanical properties were affected by the amount of CNTs in the starting precursor materials. Therefore, CNT-reinforced hydroxyapatite composite is a promising coating material for high-load-bearing metal implants.

  11. Plasma Spraying Reclaims Compressor Housings

    NASA Technical Reports Server (NTRS)

    Leissler, George W.; Yuhas, John S.

    1991-01-01

    Plasma-spraying process used to build up material in worn and pitted areas. Newly applied material remachined to specified surface contours. Effective technique for addition of metal to out-of-tolerance magnesium-alloy turbine-engine compressor housings.

  12. Hydroxyapatite Reinforced Coatings with Incorporated Detonationally Generated Nanodiamonds

    SciTech Connect

    Pramatarova, L.; Pecheva, E.; Hikov, T.; Fingarova, D.; Dimitrova, R.; Spassov, T.; Krasteva, N.; Mitev, D.

    2010-01-21

    We studied the effect of the substrate chemistry on the morphology of hydroxyapatite-detonational nanodiamond composite coatings grown by a biomimetic approach (immersion in a supersaturated simulated body fluid). When detonational nanodiamond particles were added to the solution, the morphology of the grown for 2 h composite particles was porous but more compact then that of pure hydroxyapatite particles. The nanodiamond particles stimulated the hydroxyapatite growth with different morphology on the various substrates (Ti, Ti alloys, glasses, Si, opal). Biocompatibility assay with MG63 osteoblast cells revealed that the detonational nanodiamond water suspension with low and average concentration of the detonational nanodiamond powder is not toxic to living cells.

  13. Vacuum plasma spray applications on liquid fuel rocket engines

    NASA Astrophysics Data System (ADS)

    McKechnie, T. N.; Zimmerman, F. R.; Bryant, M. A.

    1992-07-01

    The vacuum plasma spray process (VPS) has been developed by NASA and Rocketdyne for a variety of applications on liquid fuel rocket engines, including the Space Shuttle Main Engine. These applications encompass thermal barrier coatings which are thermal shock resistant for turbopump blades and nozzles; bond coatings for cryogenic titanium components; wear resistant coatings and materials; high conductivity copper, NaRloy-Z, combustion chamber liners, and structural nickel base material, Inconel 718, for nozzle and combustion chamber support jackets.

  14. Electrophoretic deposition of zinc-substituted hydroxyapatite coatings.

    PubMed

    Sun, Guangfei; Ma, Jun; Zhang, Shengmin

    2014-06-01

    Zinc-substituted hydroxyapatite nanoparticles synthesized by the co-precipitation method were used to coat stainless steel plates by electrophoretic deposition in n-butanol with triethanolamine as a dispersant. The effect of zinc concentration in the synthesis on the morphology and microstructure of coatings was investigated. It is found that the deposition current densities significantly increase with the increasing zinc concentration. The zinc-substituted hydroxyapatite coatings were analyzed by X-ray diffraction, scanning electron microscopy and Fourier transform infrared spectroscopy. It is inferred that hydroxyapatite and triethanolamine predominate in the chemical composition of coatings. With the increasing Zn/Ca ratios, the contents of triethanolamine decrease in the final products. The triethanolamine can be burnt out by heat treatment. The tests of adhesive strength have confirmed good adhesion between the coatings and substrates. The formation of new apatite layer on the coatings has been observed after 7days of immersion in a simulated body fluid. In summary, the results show that dense, uniform zinc-substituted hydroxyapatite coatings are obtained by electrophoretic deposition when the Zn/Ca ratio reaches 5%.

  15. Hot Corrosion Performance of AlO-CrO/NiCoCrAlYTa and AlO/NiCoCrAlYTa Coatings Deposited by Atmospheric Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Tao, Chong; Wang, Lei; Cheng, Nailiang; Hu, Hengfa; Liu, Yang; Song, Xiu

    2016-04-01

    AlO-CrO/NiCoCrAlYTa and AlO/NiCoCrAlYTa coatings were deposited on 316L stainless steel substrate using atmospheric plasma spraying, respectively, in order to improve the oxidation and corrosion resistance. The hot corrosion performance of the coatings at 700 and 900 °C were studied, and the detailed microstructures and phase composition of the coatings were analyzed using x-ray diffraction, scanning electron microscope with energy dispersive spectrometer, and transmission electron microscope. The results show that both coatings are structurally featured by slatted layers, consisting of amorphous phase, Cr2O3, Ni3Al, and Al2O3. The hot corrosion resistance of AlO-CrO/NiCoCrAlYTa coating is better than that of AlO/NiCoCrAlYTa coating. This improvement is attributed to lower porosity and more compact Cr2O3 in AlO-CrO/NiCoCrAlYTa coating which performs better than Al2O3 in blocking further inward progress of corrosion and oxidization.

  16. Molybdenum disilicide composites produced by plasma spraying

    SciTech Connect

    Castro, R.G.; Hollis, K.J.; Kung, H.H.; Bartlett, A.H.

    1998-05-25

    The intermetallic compound, molybdenum disilicide (MoSi{sub 2}) is being considered for high temperature structural applications because of its high melting point and superior oxidation resistance at elevated temperatures. The lack of high temperature strength, creep resistance and low temperature ductility has hindered its progress for structural applications. Plasma spraying of coatings and structural components of MoSi{sub 2}-based composites offers an exciting processing alternative to conventional powder processing methods due to superior flexibility and the ability to tailor properties. Laminate, discontinuous and in situ reinforced composites have been produced with secondary reinforcements of Ta, Al{sub 2}O{sub 3}, SiC, Si{sub 3}N{sub 4} and Mo{sub 5}Si{sub 3}. Laminate composites, in particular, have been shown to improve the damage tolerance of MoSi{sub 2} during high temperature melting operations. A review of research which as been performed at Los Alamos National Laboratory on plasma spraying of MoSi{sub 2}-based composites to improve low temperature fracture toughness, thermal shock resistance, high temperature strength and creep resistance will be discussed.

  17. Hydroxyapatite-silver nanoparticles coatings on porous polyurethane scaffold.

    PubMed

    Ciobanu, Gabriela; Ilisei, Simona; Luca, Constantin

    2014-02-01

    The present paper is focused on a study regarding the possibility of obtaining hydroxyapatite-silver nanoparticle coatings on porous polyurethane scaffold. The method applied is based on a combined strategy involving hydroxyapatite biomimetic deposition on polyurethane surface using a Supersaturated Calcification Solution (SCS), combined with silver ions reduction and in-situ crystallization processes on hydroxyapatite-polyurethane surface by sample immersing in AgNO3 solution. The morphology, composition and phase structure of the prepared samples were characterized by scanning electron microscopy coupled with energy dispersive X-ray spectroscopy (SEM-EDX), X-ray diffraction (XRD), UV-Vis spectroscopy and X-ray photoelectron spectroscopy (XPS) measurements. The data obtained show that a layer of hydroxyapatite was deposited on porous polyurethane support and the silver nanoparticles (average size 34.71 nm) were dispersed among and even on the hydroxyapatite crystals. Hydroxyapatite/polyurethane surface acts as a reducer and a stabilizing agent for silver ions. The surface plasmon resonance peak in UV-Vis absorption spectra showed an absorption maximum at 415 nm, indicating formation of silver nanoparticles. The hydroxyapatite-silver polyurethane scaffolds were tested against Staphylococcus aureus and Escherichia coli and the obtained data were indicative of good antibacterial properties of the materials.

  18. Novel nanostructured hydroxyapatite coating for dental and orthopedic implants

    NASA Astrophysics Data System (ADS)

    Liu, Huinan; Jiang, Wenping; Malshe, Ajay

    2009-09-01

    A novel hybrid coating process, combining NanoSpray® (built on electrostatic spray coating) technology with microwave sintering process, was developed for synthesizing hydroxyapatite- (HA-) based nanostructured coating with favorable properties for dental and orthopedic implants. Specifically, HA nanoparticles were deposited on commercially pure titanium substrates using NanoSpray technique to produce the HA coating, which was then sintered in a microwave furnace under controlled conditions. The study showed that the use of NanoSpray followed by microwave sintering results in nanoscale HA coating for dental/orthopedic application.

  19. Vapor Phase Deposition Using Plasma Spray-PVD™

    NASA Astrophysics Data System (ADS)

    von Niessen, K.; Gindrat, M.; Refke, A.

    2010-01-01

    Plasma spray—physical vapor deposition (PS-PVD) is a low pressure plasma spray technology to deposit coatings out of the vapor phase. PS-PVD is a part of the family of new hybrid processes recently developed by Sulzer Metco AG (Switzerland) on the basis of the well-established low pressure plasma spraying (LPPS) technology. Included in this new process family are plasma spray—chemical vapor deposition (PS-CVD) and plasma spray—thin film (PS-TF) processes. In comparison to conventional vacuum plasma spraying and LPPS, these new processes use a high energy plasma gun operated at a work pressure below 2 mbar. This leads to unconventional plasma jet characteristics which can be used to obtain specific and unique coatings. An important new feature of PS-PVD is the possibility to deposit a coating not only by melting the feed stock material which builds up a layer from liquid splats, but also by vaporizing the injected material. Therefore, the PS-PVD process fills the gap between the conventional PVD technologies and standard thermal spray processes. The possibility to vaporize feedstock material and to produce layers out of the vapor phase results in new and unique coating microstructures. The properties of such coatings are superior to those of thermal spray and EB-PVD coatings. This paper reports on the progress made at Sulzer Metco to develop functional coatings build up from vapor phase of oxide ceramics and metals.

  20. Effect of Initial Powder Morphology and Thermal and Mechanical Properties of Stand-Alone Plasma-Sprayed 7 wt%Y2O3-ZrO2 Coatings

    SciTech Connect

    Ercan, Batur; Bowman, Keith; Trice, Rodney; Wang, Hsin; Porter, Wallace D

    2006-01-01

    The effects of starting powder morphology on the thermal and mechanical properties of stand-alone plasma-sprayed 7 wt.% Y{sub 2}O{sub 3}-ZrO{sub 2}(YSZ) coatings were studied. Two powder morphologies were investigated: an agglomerated and sintered powder (referred to presently as 'AS') and a powder manufactured using plasma spheroidization to create hollow spheres (referred to presently as 'HS'). Coatings made from AS powders contained 0.21 wt.% SiO{sub 2} impurity, twice as much as observed in coatings made from HS powders. Properties of coatings made from each powder type were compared in the as-sprayed state and after 50 h heat treatments at temperatures ranging from 1000 to 1400 C. SEM microstructural investigations revealed significant differences in the porosity and distribution of pores in the coatings. In coatings made with AS powders the majority of the high aspect ratio pores were located between lamella (interlamellar porosity). In addition to interlamellar pores, coatings made with HS powders demonstrated 1.5 times more spherical-shaped globular pores by number located within lamella. Globular pores were shown to still exist in coatings made with HS powders after 50 h heat treatments at 1400 C. Archimedes porosity measurements showed that coatings made with AS powders typically contained 4-5% less total porosity than coatings made with HS powders. Thermal conductivity experiments using laser flash showed that there was no difference in the thermal conductivity of coatings made from either powder type in the as-sprayed state despite higher porosity in the coatings made from HS powders. After a 50 h heat treatment at 1000 and 1200 C, coatings made from both powder types still demonstrated statistically similar thermal conductivities. However, after a 50 h heat treatment at 1400 C the thermal conductivity of coatings made from AS powders was found to be 0.3 W/m/K higher than coatings made from HS powders. Microstructural differences in the coatings made

  1. Improved Small-Particle Powders for Plasma Spraying

    NASA Technical Reports Server (NTRS)

    Nguyen, QuynhGiao, N.; Miller, Robert A.; Leissler, George W.

    2005-01-01

    Improved small-particle powders and powder-processing conditions have been developed for use in plasma spray deposition of thermal-barrier and environmental barrier coatings. Heretofore, plasma-sprayed coatings have typically ranged in thickness from 125 to 1,800 micrometers. As explained below, the improved powders make it possible to ensure complete coverage of substrates at unprecedently small thicknesses of the order of 25 micrometers. Plasma spraying involves feeding a powder into a hot, high-velocity plasma jet. The individual powder particles melt in the plasma jet as they are propelled towards a substrate, upon which they splat to build up a coating. In some cases, multiple coating layers are required. The size range of the powder particles necessarily dictates the minimum thickness of a coating layer needed to obtain uniform or complete coverage. Heretofore, powder particle sizes have typically ranged from 40 to 70 micrometers; as a result, the minimum thickness of a coating layer for complete coverage has been about 75 micrometers. In some applications, thinner coatings or thinner coating layers are desirable. In principle, one can reduce the minimum complete-coverage thickness of a layer by using smaller powder particles. However, until now, when powder particle sizes have been reduced, the powders have exhibited a tendency to cake, clogging powder feeder mechanisms and feed lines. Hence, the main problem is one of synthesizing smaller-particle powders having desirable flow properties. The problem is solved by use of a process that begins with a spray-drying subprocess to produce spherical powder particles having diameters of less than 30 micrometers. (Spherical-particle powders have the best flow properties.) The powder is then passed several times through a commercial sifter with a mesh to separate particles having diameters less than 15 micrometers. The resulting fine, flowable powder is passed through a commercial fluidized bed powder feeder into a

  2. Electroform/Plasma-Spray Laminates for X-Ray Optics

    NASA Technical Reports Server (NTRS)

    Ulmer, Melville P.; Graham, Michael; Vaynman, Semyon

    2007-01-01

    Electroform/plasma-spray laminates have shown promise as lightweight, strong, low-thermal-expansion components for xray optics. The basic idea is to exploit both (1) the well-established art of fabrication of optical components by replication and (2) plasma spraying as a means of reinforcing a thin replica optic with one or more backing layer(s) having tailorable thermomechanical properties. In x-ray optics as in other applications, replication reduces the time and cost of fabrication because grinding and polishing can be limited to a few thick masters, from which many lightweight replicas can thereafter be made. The first step in the fabrication of a component of the type in question is to make a replica optic by electroforming a thin layer of nickel on a master. Through proper control of the electroforming process conditions, it is possible to minimize residual stress and, hence, to minimize distortion in the replica. Next, a powder comprising ceramic particles coated with a metal compatible with the electroformed nickel is plasma-sprayed onto the backside of the nickel replica. Then through several repetitions and variations of the preceding steps or perhaps a small compressive stress, alternating layers of electroformed nickel and plasma-sprayed metal-coated ceramic powder are deposited. The thicknesses of the layers and the composition of the metal-coated ceramic powder are chosen to optimize the strength, areal mass density, and toughness of the finished component. An important benefit of using both electroforming and plasma spraying is the possibility of balancing stresses to a minimum level, which could be zero or perhaps a small net compressive stress designed to enhance the function of the component in its intended application.

  3. Crystallographic texture in pulsed laser deposited hydroxyapatite bioceramic coatings

    PubMed Central

    Kim, Hyunbin; Camata, Renato P.; Lee, Sukbin; Rohrer, Gregory S.; Rollett, Anthony D.; Vohra, Yogesh K.

    2008-01-01

    The orientation texture of pulsed laser deposited hydroxyapatite coatings was studied by X-ray diffraction techniques. Increasing the laser energy density of the KrF excimer laser used in the deposition process from 5 to 7 J/cm2 increases the tendency for the c-axes of the hydroxyapatite grains to be aligned perpendicular to the substrate. This preferred orientation is most pronounced when the incidence direction of the plume is normal to the substrate. Orientation texture of the hydroxyapatite grains in the coatings is associated with the highly directional and energetic nature of the ablation plume. Anisotropic stresses, transport of hydroxyl groups and dehydroxylation effects during deposition all seem to play important roles in the texture development. PMID:18563207

  4. Effect of modification substrate on the microstructure of hydroxyapatite coating

    NASA Astrophysics Data System (ADS)

    Realpe-Jaramillo, J.; Morales-Morales, J. A.; González-Sánchez, J. A.; Cabanzo, R.; Mejía-Ospino, E.; Rodríguez-Pereira, J.

    2017-01-01

    Bioactive hydroxyapatite (HA) coatings were fabricated by a precipitation, sol-gel and dip-coating method. The effects of the aging time and the base used to adjust pH and substrate materials on the phases and microstructures of HA coatings were studied by field emission scanning electron microscopy FESEM, energy dispersive spectroscopy EDS, X-ray photoelectron spectroscopy XPS, and the vibrations of the phosphate groups were determined by Raman spectroscopy. The results showed that all the films were composed of the phases of TiO2 and HA. With coated titanium substrate with TiO2, the crystallinity of the HA coating increases, the structure became more compact and the Ca/P ratio increased because of the loss of P in the films. The addition of sodium hydroxide (adjusting the pH level to about 10) can increase the HA content in the coating. XPS and EDS results for steel substrate and titanium showed poor calcium content as obtained with a Ca/P ratio of 1.38 and 1.58, respectively, composition is similar to that of natural apatite. However, spectroscopic results suggest the presence of a mixture of hydroxyapatite and octacalcium phosphate. The different substrate materials have a high influence on the microstructure of the separated double films. However, hydroxyapatite nanopowders coatings were obtained using a simple method, with potential biomedical applications.

  5. Influence of the Surface State on the Adherence of the Coating: Case of an Alumina Coating Plasma Sprayed on SiC Composites

    NASA Astrophysics Data System (ADS)

    Costil, S.; Lukat, S.; Verdy, C.; Coddet, C.

    2011-01-01

    In thermal spraying, adherence between the coating and the substrate appears as the fundamental point. To favor a good interaction between both, it is often necessary to clean and prepare the substrate surface. Conventionally, solvents and sand blasting are applied to remove the contaminants and increase the surface roughness for a mechanical anchorage. However, according to the substrate nature (ceramic) or the substrate morphology, it can be prejudicial to apply a mechanical treatment because of peeling of the surface or a decrease in the global properties. Then, to obtain an appropriate preparation, several techniques can be investigated, such as water jet, ice blasting, and heat treatment; as well, laser ablation can be an interesting technology to prepare the substrate surface. The aim of this work was to study the modifications induced by 10 ns single or cumulative pulses of a Q-switched Nd:YAG near-infrared laser and its influence on the interface adhesion. The case of an alumina coating sprayed on a ceramic matrix composite (CMC) was studied. In these conditions, the laser treatment seems favorable from the adherence viewpoint according to the mechanical effect (induced by a conelike structure) and the chemical effect.

  6. Plasma sprayed ceria-containing interlayer

    DOEpatents

    Schmidt, Douglas S.; Folser, George R.

    2006-01-10

    A plasma sprayed ceria-containing interlayer is provided. The interlayer has particular application in connection with a solid oxide fuel cell used within a power generation system. The fuel cell advantageously comprises an air electrode, a plasma sprayed interlayer disposed on at least a portion of the air electrode, a plasma sprayed electrolyte disposed on at least a portion of the interlayer, and a fuel electrode applied on at least a portion of the electrolyte.

  7. Modelling the Plasma Jet in Multi-Arc Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Bobzin, K.; Öte, M.; Schein, J.; Zimmermann, S.; Möhwald, K.; Lummer, C.

    2016-08-01

    Particle in-flight characteristics in atmospheric plasma spraying process are determined by impulse and heat energy transferred between the plasma jet and injected powder particles. One of the important factors for the quality of the plasma-sprayed coatings is thus the distribution of plasma gas temperatures and velocities in plasma jet. Plasma jets generated by conventional single-arc plasma spraying systems and their interaction with powder particles were subject matter of intensive research. However, this does not apply to plasma jets generated by means of multi-arc plasma spraying systems yet. In this study, a numerical model has been developed which is designated to dealing with the flow characteristics of the plasma jet generated by means of a three-cathode spraying system. The upstream flow conditions, which were calculated using a priori conducted plasma generator simulations, have been coupled to the plasma jet simulations. The significances of the relevant numerical assumptions and aspects of the models are analyzed. The focus is placed on to the turbulence and diffusion/demixing modelling. A critical evaluation of the prediction power of the models is conducted by comparing the numerical results to the experimental results determined by means of emission spectroscopic computed tomography. It is evident that the numerical models exhibit a good accuracy for their intended use.

  8. Plasma sprayed Fe(76)Nd(16)B(8) permanent magnets

    NASA Technical Reports Server (NTRS)

    Overfelt, R. A.; Anderson, C. D.; Flanagan, W. F.

    1986-01-01

    Thin coatings (0.16 mm) and thick coatings (0.50 mm) of Fe(76)Nd(16)B(8) were deposited on stainless-steel substrates by low pressure plasma spraying. Microscopic examination of the coatings in a light microscope revealed excessive porosity, but good bonding to the substrate. Fracture cross sections examined in a scanning electron microscope showed the grains to be equiaxed and approximately 1 micron or less in diameter in the as-sprayed condition. The intrinsic coercivities of the as-sprayed coatings varied from 5.8 to 10.9 kOe. The effects of postspray heat treatments on the intrinsic coercivity are also given.

  9. Hot Corrosion Mechanism in Multi-Layer Suspension Plasma Sprayed Gd2Zr2O7 /YSZ Thermal Barrier Coatings in the Presence of V2O5 + Na2SO4

    NASA Astrophysics Data System (ADS)

    Jonnalagadda, Krishna Praveen; Mahade, Satyapal; Curry, Nicholas; Li, Xin-Hai; Markocsan, Nicolaie; Nylén, Per; Björklund, Stefan; Peng, Ru Lin

    2017-01-01

    This study investigates the corrosion resistance of two-layer Gd2Zr2O7/YSZ, three-layer dense Gd2Zr2O7/ Gd2Zr2O7/YSZ, and a reference single-layer YSZ coating with a similar overall top coat thickness of 300-320 µm. All the coatings were manufactured by suspension plasma spraying resulting in a columnar structure except for the dense layer. Corrosion tests were conducted at 900 °C for 8 h using V2O5 and Na2SO4 as corrosive salts at a concentration of approximately 4 mg/cm2. SEM investigations after the corrosion tests show that Gd2Zr2O7-based coatings exhibited lower reactivity with the corrosive salts and the formation of gadolinium vanadate (GdVO4), accompanied by the phase transformation of zirconia was observed. It is believed that the GdVO4 formation between the columns reduced the strain tolerance of the coating and also due to the fact that Gd2Zr2O7 has a lower fracture toughness value made it more susceptible to corrosion-induced damage. Furthermore, the presence of a relatively dense layer of Gd2Zr2O7 on the top did not improve in reducing the corrosion-induced damage. For the reference YSZ coating, the observed corrosion-induced damage was lower probably due to combination of more limited salt penetration, the SPS microstructure and superior fracture toughness of YSZ.

  10. Phase distributions in plasma-sprayed zirconia-yttria

    NASA Technical Reports Server (NTRS)

    Miller, R. A.; Garlick, R. G.; Smialek, J. L.

    1983-01-01

    The distribution of phases in plasma-sprayed zirconia-yttria has been determined over a range of yttria levels from 0 to 26.1 molpct YO(1.5) using room temperature X-ray diffractometry. Pure, plasma-sprayed zirconia is composed almost entirely of the monoclinic phase. At levels of yttria between 4 and 10 percent, a quenched-in tetragonal phase predominates, and at higher levels the cubic phase predominates. The phase distributions are compared with previously reported test lives of thermal barrier coatings formed from these materials. Regions of optimal lives were found to correlate with regions having high amounts of the tetragonal phase, small but nonzero amounts of the monoclinic phase, and little or none of the cubic phase. Possible relationships between phase composition and coating performance are discussed.

  11. Effects of plasma spray parameters on two layer thermal barrier

    NASA Technical Reports Server (NTRS)

    Stecura, S.

    1981-01-01

    The power level and the type of arc gas used during plasma spraying of a two layer thermal barrier system (TBS) were found to affect the life of the system. Life at 1095 C in a cyclic furnace test was improved by about 140 percent by increasing the power during plasma spray applications of the bond and thermal barrier coatings. This improvement is due to increases in the densities of the bond and thermal barrier coatings by 3 and 5 percent, respectively. These increases in densities are equivalent to about 45 and 30 percent reduction in mean porosities, respectively. The addition of hydrogen to the argon arc gas had the same effect as the reduction in power level and caused a reduction in TBS life.

  12. Recent developments in plasma spray processes for applications in energy technology

    NASA Astrophysics Data System (ADS)

    Mauer, G.; Jarligo, M. O.; Marcano, D.; Rezanka, S.; Zhou, D.; Vaßen, R.

    2017-03-01

    This work focuses on recent developments of plasma spray processes with respect to specific demands in energy technology. High Velocity Atmospheric Plasma Spraying (HV-APS) is a novel variant of plasma spraying devoted to materials which are prone to oxidation or decomposition. It is shown how this process can be used for metallic bondcoats in thermal barrier coating systems. Furthermore, Suspension Plasma Spraying (SPS) is a new method to process submicron-sized feedstock powders which are not sufficiently flowable to feed them in dry state. SPS is presently promoted by the development of novel torch concepts with axial feedstock injection. An example for a columnar structured double layer thermal barrier coating is given. Finally, Plasma Spray-Physical Vapor Deposition (PS-PVD) is a novel technology operating in controlled atmosphere at low pressure and high plasma power. At such condition, vaporization even of high-melting oxide ceramics is possible enabling the formation of columnar structured, strain tolerant coatings with low thermal conductivity. Applying different conditions, the deposition is still dominated by liquid splats. Such process is termed Low Pressure Plasma Spraying-Thin Film (LPPS-TF). Two examples of applications are gas-tight and highly ionic and electronic conductive electrolyte and membrane layers which were deposited on porous metallic substrates.

  13. Functionally Graded Hydroxyapatite Coatings Doped with Antibacterial Components

    SciTech Connect

    Bai, Xiao; More, Karren Leslie; Rouleau, Christopher M; Rabiei, Afsaneh

    2010-01-01

    A series of functionally graded hydroxyapatite (FGHA) coatings incorporated with various percentages of silver were deposited on titanium substrates using ion beam assisted deposition (IBAD). The analysis of the coating s cross-section using transmission electron microscopy (TEM) and scanning transmission electron microscopy (STEM), equipped with energy dispersive X-ray spectroscopy (EDS), has shown a decreased crystallinity as well as a distribution of nano scale (10 ~ 50nm) silver particles from the coating/substrate interface to top surface. Both X-ray diffraction (XRD) and fourier transform infrared spectroscopy (FTIR) results revealed the presence of hydroxyapatite within the coatings. The amount of Ag (wt. %) on the outer surface of the FGHA, as determined from X-ray photoelectron spectroscopy (XPS), ranged from 1.09 ~ 6.59, which was about half of the average Ag wt. % incorporated in the entire coating. Average adhesion strengths evaluated by pull-off tests were in the range of 83 6 - 88 3 MPa, which is comparable to 85 MPa for FGHA without silver. Further optical observations of failed areas illustrated that the dominant failure mechanism was epoxy failure and FGHA coating delamination was not observed.

  14. Interfacial bond strength of electrophoretically deposited hydroxyapatite coatings on metals.

    PubMed

    Wei, M; Ruys, A J; Swain, M V; Kim, S H; Milthorpe, B K; Sorrell, C C

    1999-07-01

    Hydroxyapatite (HAp) coatings were deposited onto substrates of metal biomaterials (Ti, Ti6Al4V, and 316L stainless steel) by electrophoretic deposition (EPD). Only ultra-high surface area HAp powder, prepared by the metathesis method 10Ca(NO3)2 + 6(NH4)2HPO4 + 8NH4OH), could produce dense coatings when sintered at 875-1000degreesC. Single EPD coatings cracked during sintering owing to the 15-18% sintering shrinkage, but the HAp did not decompose. The use of dual coatings (coat, sinter, coat, sinter) resolved the cracking problem. Scanning electron microscopy/energy dispersive spectroscopy (SEM/EDS) inspection revealed that the second coating filled in the "valleys" in the cracks of the first coating. The interfacial shear strength of the dual coatings was found, by ASTM F1044-87, to be approximately 12 MPa on a titanium substrate and approximately 22 MPa on 316L stainless steel, comparing quite favorably with the 34 MPa benchmark (the shear strength of bovine cortical bone was found to be 34 MPa). Stainless steel gave the better result since -316L (20.5 microm mK(-1)) > alpha-HAp (approximately 14 microm mK(-1)), resulting in residual compressive stresses in the coating, whereas alpha-titanium (approximately 10.3 microm mK(-1)) < alpha-HAp, resulting in residual tensile stresses in the coating.

  15. Microstructural disintegration in dense hydroxyapatite and hydroxyapatite-coated metal implants

    NASA Astrophysics Data System (ADS)

    Seo, Dong Seok; Lee, Jong Kook

    2007-08-01

    Hydroxyapatite (HA) has been widely used as a coating for orthopedic metal implants. An important concern regarding HA coating is its degradation of the biological milieu. In this study, the microstructure of a retrieved HA-coated acetabular cup implanted for four years after total hip arthroplasty (THA) was investigated by field emission scanning electron microscopy. In order to understand the underlying mechanism, of degradation and exfoliation of the HA coating, degradation of phase-pure and dense HA ceramics was also observed by in vitro and in vivo testing. The surface morphology and fracture surfaces of HA ceramics revealed that the dissolution starting at the surface extended inwards resulting in particle loosening and microstructural-level degradation. The dissolution features of HA ceramics were similar to the case of HA coating. It was found that extensive dissolution of the coating occurred and most of the coating disappeared. The majority of the remaining graints were fractured by the intergranular mode, suggesting that grain boundaries should be predominantly dissolved. These observations may explain the mechanism through which the biological stability of the HA coated layer becomes unexpectedly poor.

  16. Corrosion protection performance of porous strontium hydroxyapatite coating on polypyrrole coated 316L stainless steel.

    PubMed

    Gopi, D; Ramya, S; Rajeswari, D; Kavitha, L

    2013-07-01

    Polypyrrole/strontium hydroxyapatite bilayer coatings were achieved on 316L stainless steel (316L SS) by the electropolymerisation of pyrrole from sodium salicylate solution followed by the electrodeposition of porous strontium hydroxyapatite. The formation and the morphology of the bilayer coatings were characterised by Fourier transform infrared spectroscopy (FT-IR) and high resolution scanning electron microscopy (HRSEM), respectively. The corrosion resistance of the coated 316L SS specimens was investigated in Ringer's solution by electrochemical techniques and the results were substantiated with inductively coupled plasma atomic emission spectrometry (ICP-AES). The passive film underneath the polypyrrole layer is effective in protecting 316L SS against corrosion in Ringer's solution. Moreover, we believe that the top porous strontium hydroxyapatite layer can provide potential bioactivity to the 316L SS.

  17. Characterization of Microplasma Sprayed Hydroxyapatite Coating

    NASA Astrophysics Data System (ADS)

    Dey, Arjun; Mukhopadhyay, Anoop K.; Gangadharan, S.; Sinha, Mithilesh K.; Basu, Debabrata

    2009-12-01

    Microplasma sprayed (MIPS) HAP coatings on SS316L substrates were characterized by x-ray diffraction, Fourier transformed infrared spectroscopy, optical microscopy, scanning electron microscopy (SEM), field emission scanning electron microscopy (FE-SEM), atomic force microscopy and image analysis. The coating showed a high degree of crystallinity ~92%, a high porosity level of 20 vol.% and a moderate bonding strength of about 13 MPa. The displacement controlled three-point bend tests and associated results of optical microscopy indicated that crack deflection, crack branching, and also local crack bridging occurred during crack propagation in the coating. The nano-hardness ( H) and Young’s modulus ( E) of the MIPS-HAP coatings as measured by nanoindentation technique were about 6 and 92 GPa, respectively. The fracture toughness ( K ic) of the coating was ~0.6 MPa·m0.5. From the nano-scratch experiments, the critical normal load at which localized microcracking led to delamination was measured to be ~400 mN.

  18. Sol-gel hydroxyapatite coatings on stainless steel substrates.

    PubMed

    Liu, Dean-Mo; Yang, Quanzu; Troczynski, Tom

    2002-02-01

    Thin film hydroxyapatite deposits onto sandblasted 316L stainless steel substrates were prepared using water-based sol-gel technique recently developed in our lab. The coatings were annealed in air at 375 degrees C, 400 degrees C, and 500 degrees C. Phase formation, surface morphology, interfacial microstructure, and interfacial bonding strength of the coatings were investigated. Apatitic structure developed within the coatings while annealing at temperatures > or = 400 degrees C, while those heat-treated at 375 degrees C showed poor crystallinity. The coatings were dense and firmly attached to the underlying substrates, reaching an average bonding strength (as determined through the pull-out test) of 44 MPa. Nano-porous structure was found for the coatings annealed at 500 degrees C, believed to result from grain growth, and causing a slight decrease in the bonding strength. Surface microcracking, although not extensive, occurred after annealing at temperatures > or = 400 degrees C, and was linked to non-uniform thickness of the coating due to roughness of the substrate. A contraction of the coatings as a result of sintering, and phase transition from amorphous (or poor crystalline) to reasonably good crystalline apatite, may be responsible for the loss of structural integrity of the thicker sections of the coatings. It seems quite promising that a dense and adhesive apatite coating can be achieved through water-based sol gel technology after short-term annealing at around 400 degrees C in air.

  19. Influence of Starting Powders on Hydroxyapatite Coatings Fabricated by Room Temperature Spraying Method.

    PubMed

    Seo, Dong Seok; Lee, Jong Kook; Hwang, Kyu Hong; Hahn, Byung Dong; Yoon, Seog Young

    2015-08-01

    Three types of raw materials were used for the fabrication of hydroxyapatite coatings by using the room temperature spraying method and their influence on the microstructure and in vitro characteristics were investigated. Starting hydroxyapatite powders for coatings on titanium substrate were prepared by a heat treatment at 1100 °C for 2 h of bovine bone, bone ash, and commercial hydroxyapatite powders. The phase compositions and Ca/P ratios of the three hydroxyapatite coatings were similar to those of the raw materials without decomposition or formation of a new phase. All hydroxyapatite coatings showed a honeycomb structure, but their surface microstructures revealed different features in regards to surface morphology and roughness, based on the staring materials. All coatings consisted of nano-sized grains and had dense microstructure. Inferred from in vitro experiments in pure water, all coatings have a good dissolution-resistance and biostability in water.

  20. Dependence of scale thickness on the breaking behavior of the initial oxide on plasma spray bond coat surface during vacuum pre-treatment

    NASA Astrophysics Data System (ADS)

    Zhang, Bang-Yan; Meng, Guo-Hui; Yang, Guan-Jun; Li, Cheng-Xin; Li, Chang-Jiu

    2017-03-01

    The thermally grown oxide (TGO) on the thermal spray bond coat surface was one of the most important factors which would influence the lifetime of thermal barrier coatings (TBCs). Pre-diffusion treatment (high temperature vacuum treatment) plays an important role in the growth of the TGO. Results show that the initial thin oxide scale, formed during deposition process, on the as-sprayed bond coating surface has broken and shrunk to discontinuous oxide particles through the elements diffusion during the pre-diffusion. Two kinds of bond coats with different initial oxide scale thicknesses were subjected to the same pre-diffusion. The two pre-diffused bond coats show different results of the average distance between the individual oxide particles. In this study, a three dimensional model with thermal grooving theory was developed to explore the essential condition for the scale breaking and explain the differences of these results. This research can provide reference for the preparation optimization and pre-treatment optimization of bond coat towards high performance TBCs.

  1. Plasma spray forming metals, intermetallics, and composites

    NASA Astrophysics Data System (ADS)

    Sampath, Sanjay; Herman, Herbert

    1993-07-01

    Plasma spray processing is a droplet deposition method that combines the steps of melting, rapid solidification, and consolidation into a single step. The versatility of the technology enables the processing of freestanding bulk, near-net shapes of a wide range of alloys, intermetallics, ceramics, and composites, while still retaining the benefits of rapid solidification processing. In particular, it is possible to produce dense forms through vacuum plasma spraying.

  2. Nano hydroxyapatite-coated implants improve bone nanomechanical properties.

    PubMed

    Jimbo, R; Coelho, P G; Bryington, M; Baldassarri, M; Tovar, N; Currie, F; Hayashi, M; Janal, M N; Andersson, M; Ono, D; Vandeweghe, S; Wennerberg, A

    2012-12-01

    Nanostructure modification of dental implants has long been sought as a means to improve osseointegration through enhanced biomimicry of host structures. Several methods have been proposed and demonstrated for creating nanotopographic features; here we describe a nanoscale hydroxyapatite (HA)-coated implant surface and hypothesize that it will hasten osseointegration and improve its quality relative to that of non-coated implants. Twenty threaded titanium alloy implants, half prepared with a stable HA nanoparticle surface and half grit-blasted, acid-etched, and heat-treated (HT), were inserted into rabbit femurs. Pre-operatively, the implants were morphologically and topographically characterized. After 3 weeks of healing, the samples were retrieved for histomorphometry. The nanomechanical properties of the surrounding bone were evaluated by nanoindentation. While both implants revealed similar bone-to-implant contact, the nanoindentation demonstrated that the tissue quality was significantly enhanced around the HA-coated implants, validating the postulated hypothesis.

  3. Manufacturing of Composite Coatings by Atmospheric Plasma Spraying Using Different Feed-Stock Materials as YSZ and MoSi2

    NASA Astrophysics Data System (ADS)

    Koch, D.; Mauer, G.; Vaßen, R.

    2017-02-01

    Yttria-stabilized zirconia (YSZ) is the state-of-the-art material for the top coat of thermal barrier coatings. To increase the efficiency and lifetime of gas turbines, the integration of MoSi2 as a healing material was proposed. A new method of manufacture was explored in order to enable the spraying of a homogeneous mixed layer of YSZ and MoSi2. As the chemical and physical properties of these powders are very different, they require contrasting process conditions. Due to the evaporation of Si from MoSi2 at spraying conditions suitable for YSZ, more moderate conditions and a shorter time of flight are required for depositing MoSi2. At the same time, the spraying conditions still need to be sufficient for melting the YSZ particles in order to produce a coating. To obtain a homogeneous mixture, both conditions can be matched using an injection system that allows powder injection at two different locations of the plasma jet. Two-color pyrometry during flight (DPV-2000, Tecnar) was used to monitor the actual particle temperature. By optimizing the injection point for the MoSi2, a mixed coating was obtained without decomposition of the MoSi2, which has been analyzed by means of XRD and SEM.

  4. Deformation and Tensile Cyclic Fatigue of Plasma-Sprayed ZrO2-8wt% Y2O3 Thermal Barrier Coatings

    NASA Technical Reports Server (NTRS)

    Choi, Sung R.; Zhu, Dong-Ming; Miller, Robert A.

    2001-01-01

    Deformation (constitutive relations) of free-standing, thick thermal barrier coatings of sprayed ZrO2-8Wt% Y2O3 was determined at ambient temperature in both pure tension and pure compression using cylindrical bar test specimens. The material exhibited both significant nonlinearity and hysteresis in its load-strain curves, The load-strain relations in four-point uniaxial flexure were determined from tension and compression sides and were compared with individual pure tension and compression constitutive data. Effect of sintering on deformation behavior was significant, resulting in a dramatic change in constitutive relation. Cyclic fatigue testing of the coating material in tension-tension at room temperature showed an insignificant susceptibility to fatigue, similar to the slow crack growth behavior of the material in flexure in 800 C air.

  5. Stress rupture and creep behavior of a low pressure plasma-sprayed NiCoCrAlY coating alloy in air and vacuum

    NASA Technical Reports Server (NTRS)

    Hebsur, M. G.; Miner, R. V.

    1987-01-01

    The creep behavior of a NiCoCrAlY coating alloy in air and vacuum at 660 and 850 C is studied. The microstructure of the coating alloy is described. Analysis of the creep curves reveal that the secondary creep rates, the transition from secondary to tertiary creep, and the strain-to-failure are affected by the environment, preexposure, stress, and temperature. It is observed that the rupture lives of the NiCoCrAlY alloy at 660 and 850 C are greater in air than in vacuum. Several mechanisms that may explain the lack of crack growth from surface-connected pores during tests in air are proposed.

  6. Electrophoretic deposition of composite hydroxyapatite-silica-chitosan coatings

    SciTech Connect

    Grandfield, K.; Zhitomirsky, I.

    2008-01-15

    Electrophoretic deposition (EPD) method has been developed for the fabrication of nanocomposite silica-chitosan coatings. Cathodic deposits were obtained on various conductive substrates using suspensions of silica nanoparticles in a mixed ethanol-water solvent, containing dissolved chitosan. Co-deposition of silica and hydroxyapatite (HA) nanoparticles resulted in the fabrication of HA-silica-chitosan coatings. The deposition yield has been studied at a constant voltage mode at various deposition durations. The method enabled the formation of coatings of different thickness in the range of up to 100 {mu}m. Deposit composition, microstructure and porosity can be varied by variation of HA and silica concentration in the suspensions. It was demonstrated that EPD can be used for the fabrication of HA-silica-chitosan coatings of graded composition and laminates. The method enabled the deposition of coatings containing layers of silica-chitosan and HA-chitosan nanocomposites using suspensions with different HA and silica content. Obtained coatings were studied by X-ray diffraction, thermogravimetric and differential thermal analysis, scanning electron microscopy and energy dispersive spectroscopy. The mechanism of deposition is discussed.

  7. Crystalline hydroxyapatite coatings synthesized under hydrothermal conditions on modified titanium substrates.

    PubMed

    Suchanek, Katarzyna; Bartkowiak, Amanda; Gdowik, Agnieszka; Perzanowski, Marcin; Kąc, Sławomir; Szaraniec, Barbara; Suchanek, Mateusz; Marszałek, Marta

    2015-06-01

    Hydroxyapatite coatings were successfully produced on modified titanium substrates via hydrothermal synthesis in a Ca(EDTA)(2-) and (NH4)2HPO4 solution. The morphology of modified titanium substrates as well as hydroxyapatite coatings was studied using scanning electron microcopy and phase identification by X-ray diffraction, and Raman and FTIR spectroscopy. The results show that the nucleation and growth of hydroxyapatite needle-like crystals with hexagonal symmetry occurred only on titanium substrates both chemically and thermally treated. No hydroxyapatite phase was detected on only acid etched Ti metal. This finding demonstrates that only a particular titanium surface treatment can effectively induce the apatite nucleation under hydrothermal conditions.

  8. Investigation on the effect of collagen and vitamins on biomimetic hydroxyapatite coating formation on titanium surfaces.

    PubMed

    Ciobanu, Gabriela; Ciobanu, Octavian

    2013-04-01

    This study uses an in vitro experimental approach to investigate the roles of collagen and vitamins in regulating the deposition of hydroxyapatite layer on the pure titanium surface. Titanium implants were coated with a hydroxyapatite layer under biomimetic conditions by using a supersaturated calcification solution (SCS), modified by adding vitamins A and D3, and collagen. The hydroxyapatite deposits on titanium were investigated by means of scanning electron microscopy (SEM) coupled with X-ray analysis (EDX), X-ray photoelectron spectroscopy (XPS), X-ray diffraction (XRD) and Fourier transformed infrared (FTIR) spectroscopy. The results obtained have shown that hydroxyapatite coatings were produced in vitro under vitamins and collagen influence.

  9. Does hydroxyapatite coating have no advantage over porous coating in primary total hip arthroplasty? A meta-analysis.

    PubMed

    Chen, Yun-Lin; Lin, Tiao; Liu, An; Shi, Ming-Min; Hu, Bin; Shi, Zhong-Li; Yan, Shi-Gui

    2015-01-28

    There are some arguments between the use of hydroxyapatite and porous coating. Some studies have shown that there is no difference between these two coatings in total hip arthroplasty (THA), while several other studies have shown that hydroxyapatite has advantages over the porous one. We have collected the studies in Pubmed, MEDLINE, EMBASE, and the Cochrane library from the earliest possible years to present, with the search strategy of "(HA OR hydroxyapatite) AND ((total hip arthroplasty) OR (total hip replacement)) AND (RCT* OR randomiz* OR control* OR compar* OR trial*)". The randomized controlled trials and comparative observation trials that evaluated the clinical and radiographic effects between hydroxyapatite coating and porous coating were included. Our main outcome measurements were Harris hip score (HHS) and survival, while the secondary outcome measurements were osteolysis, radiolucent lines, and polyethylene wear. Twelve RCTs and 9 comparative observation trials were included. Hydroxyapatite coating could improve the HHS (p < 0.01), reduce the incidence of thigh pain (p = 0.01), and reduce the incidence of femoral osteolysis (p = 0.01), but hydroxyapatite coating had no advantages on survival (p = 0.32), polyethylene wear (p = 0.08), and radiolucent lines (p = 0.78). Hydroxyapatite coating has shown to have an advantage over porous coating. The HHS and survival was duration-dependent-if given the sufficient duration of follow-up, hydroxyapatite coating would be better than porous coating for the survival. The properties of hydroxyapatite and the implant design had influence on thigh pain incidence, femoral osteolysis, and polyethylene wear. Thickness of 50 to 80 μm and purity larger than 90% increased the thigh pain incidence. Anatomic design had less polyethylene wear.

  10. Osseointegration of a hydroxyapatite-coated multilayered mesh stem.

    PubMed

    Kusakabe, Hiroshi; Sakamaki, Toyonori; Nihei, Kotaro; Oyama, Yasuo; Yanagimoto, Shigeru; Ichimiya, Masaru; Kimura, Jun; Toyama, Yoshiaki

    2004-07-01

    A new type of porous coating for hip prostheses called "multilayered mesh" was tested under weight-bearing conditions. The surface of the stem is constructed of titanium mesh produced by etching. The hip stems of hydroxyapatite (HA)-coated multilayered mesh and conventional beads were implanted into canine right hips, and animals were killed 3, 6 and 10 weeks and 6 and 12 months after implantation. Shear strength between the implant and the bone was evaluated by the push-out test. Bone ingrowth was calculated from backscattered electron imaging-scanning electron microscopy (BEI-SEM) images of transverse sections. Toluidine blue stained sections and the BEI-SEM images were evaluated histologically. The break sites of the specimens after the push-out test were evaluated on BEI-SEM images of longitudinal sections. The mean push-out strength of the HA-coated multilayered mesh samples was greater than that of the beads-coated samples every time tested, and the HA-coated multilayered mesh implants had significantly stronger push-out strength at 3 and 6 weeks (p<0.05). The strength of the HA-coated multilayered mesh implants was even greater at 6 and 12 months, whereas the strength of the beads-coated samples decreased. The HA-coated multilayered mesh implants showed significantly higher percentages of bone ingrowth than the beads-coated implants every time tested, except at 6 months (p<0.05). At 6 and 12 months, the bone ingrowth data for the HA-coated multilayered mesh implants increased, whereas it decreased for the beads-coated implants. The new bone formation had reached the bottom of the porous area of the HA-coated multilayered mesh surface by 3 weeks, but not had reached the bottom of the conventional beads surface. At 6 and 12 months, the smaller pores of the bead surface stopped the thickening of trabecular bone, and at 12 months, the break sites were at the bone-implant interface of the bead surface, whereas they were on the bone side of the HA-coated

  11. Osteoconductive hydroxyapatite coated PEEK for spinal fusion surgery

    NASA Astrophysics Data System (ADS)

    Hahn, Byung-Dong; Park, Dong-Soo; Choi, Jong-Jin; Ryu, Jungho; Yoon, Woon-Ha; Choi, Joon-Hwan; Kim, Jong-Woo; Ahn, Cheol-Woo; Kim, Hyoun-Ee; Yoon, Byung-Ho; Jung, In-Kwon

    2013-10-01

    Polyetheretherketone (PEEK) has attracted much interest as biomaterial for interbody fusion cages due to its similar stiffness to bone and good radio-transparency for post-op visualization. Hydroxyapatite (HA) coating stimulates bone growth to the medical implant. The objective of this work is to make an implant consisting of biocompatible PEEK with an osteoconductive HA surface for spinal or orthopedic applications. Highly dense and well-adhered HA coating was developed on medical-grade PEEK using aerosol deposition (AD) without thermal degradation of the PEEK. The HA coating had a dense microstructure with no cracks or pores, and showed good adhesion to PEEK at adhesion strengths above 14.3 MPa. The crystallinity of the HA coating was remarkably enhanced by hydrothermal annealing as post-deposition heat-treatment. In addition, in vitro and in vivo biocompatibility of PEEK, in terms of cell adhesion morphology, cell proliferation, differentiation, and bone-to-implant contact ratio, were remarkably enhanced by the HA coating through AD.

  12. Plasma-Sprayed Titanium Patterns for Enhancing Early Cell Responses

    NASA Astrophysics Data System (ADS)

    Shi, Yunqi; Xie, Youtao; Pan, Houhua; Zheng, Xuebin; Huang, Liping; Ji, Fang; Li, Kai

    2016-06-01

    Titanium coating has been widely used as a biocompatible metal in biomedical applications. However, the early cell responses and long-term fixation of titanium implants are not satisfied. To obviate these defects, in this paper, micro-post arrays with various widths (150-1000 μm) and intervals (100-300 μm) were fabricated on the titanium substrate by template-assisted plasma spraying technology. In vitro cell culture experiments showed that MC3T3-E1 cells exhibited significantly higher osteogenic differentiation as well as slightly improved adhesion and proliferation on the micro-patterned coatings compared with the traditional one. The cell number on the pattern with 1000 µm width reached 130% after 6 days of incubation, and the expressions of osteopontin (OPN) as well as osteocalcin (OC) were doubled. No obvious difference was found in cell adhesion on various size patterns. The present micro-patterned coatings proposed a new modification method for the traditional plasma spraying technology to enhance the early cell responses and convenience for the bone in-growth.

  13. Strontium and zoledronate hydroxyapatites graded composite coatings for bone prostheses.

    PubMed

    Boanini, Elisa; Torricelli, Paola; Sima, Felix; Axente, Emanuel; Fini, Milena; Mihailescu, Ion N; Bigi, Adriana

    2015-06-15

    Both strontium and zoledronate (ZOL) are known to be useful for the treatment of bone diseases associated to the loss of bone substance. In this work, we applied an innovative technique, Combinatorial Matrix-Assisted Pulsed Laser Evaporation (C-MAPLE), to deposit gradient thin films with variable compositions of Sr-substituted hydroxyapatite (SrHA) and ZOL modified hydroxyapatite (ZOLHA) on Titanium substrates. Compositional gradients were obtained by simultaneous laser vaporization of the two distinct material targets. The coatings display good crystallinity and granular morphology, which do not vary with composition. Osteoblast-like MG63 cells and human osteoclasts were co-cultured on the thin films up to 21 days. The results show that Sr counteracts the negative effect of relatively high concentration of ZOL on osteoblast viability, whereas both Sr and ZOL enhance extracellular matrix deposition. In particular, ZOL promotes type I collagen production, whereas Sr increases the production of alkaline phosphatase. Moreover, ZOL exerts a greater effect than Sr on osteoprotegerin/RANKL ratio and, as a consequence, on the reduction of osteoclast proliferation and activity. The deposition method allows to modulate the composition of the thin films and hence the promotion of bone growth and the inhibition of bone resorption.

  14. Nanocrystalline Hydroxyapatite/Si Coating by Mechanical Alloying Technique

    PubMed Central

    Hannora, Ahmed E.; Mukasyan, Alexander S.; Mansurov, Zulkhair A.

    2012-01-01

    A novel approach for depositing hydroxyapatite (HA) films on titanium substrates by using mechanical alloying (MA) technique has been developed. However, it was shown that one-hour heat treatment at 800°C of such mechanically coated HA layer leads to partial transformation of desired HA phase to beta-tri-calcium phosphate (β-TCP) phase. It appears that the grain boundary and interface defects formed during MA promote this transformation. It was discovered that doping HA by silicon results in hindering this phase transformation process. The Si-doped HA does not show phase transition to β-TCP or decomposition after heat treatment even at 900°C. PMID:22312324

  15. Biomechanical evaluation of different hydroxyapatite coatings on titanium for keratoprosthesis

    NASA Astrophysics Data System (ADS)

    Dong, Ying; Qiu, Zhiye; Liu, Xiaoyu; Wang, Liqiang; Yang, Jingxin; Huang, Yifei; Cui, Fuzhai

    2015-09-01

    Stable tissue integration is important to keratoprosthesis (KPro). The aim of this study was to evaluate the tissue bonding ability of hydroxyapatite (HAp)-coated titanium KPro. The samples were divided into three groups: test groups (IBAD group and AD group) and Ti control. The coated samples had a HAp layer created by ion beam assisted deposition (IBAD) or aerosol deposition (AD). The surface characteristics were analyzed with SEM, AFM, and XRD. The samples were surgically inserted into the muscles of rabbits. Eight weeks after healing, the attachment to the tissue was tested with a universal test device. The three samples exhibited distinctive surface morphology. The force to remove the HAp implants from the muscles was significantly greater than that of Ti group ( P < 0.01), with the AD samples requiring the greatest force ( P < 0.01). After removal, SEM showed that the tissue was firmly attached to the surface of AD samples. Photomicrographs of the peri-implant muscles showed a layer of aligned fibrous tissue without severe inflammation. The AD samples had more fibroblasts. Results indicate that because of enhanced mechanical adhesion of soft tissue to the implants, HAp-coated Ti by AD is a suitable KPro skirt material.

  16. A sputtered zirconia primer for improved thermal shock resistance of plasma-sprayed ceramic turbine seals

    NASA Technical Reports Server (NTRS)

    Bill, R. C.; Sovey, J.; Allen, G. P.

    1981-01-01

    It is shown that the application of sputtered Y2O3-stabilized ZrO2 (YSZ) primer in plasma-sprayed YSZ ceramic-coated turbine blades results in an improvement, by a factor of 5-6, in the thermal shock life of specimens with a sprayed, porous, Ni-Cr-Al-Y intermediate layer. Species with and without the primer were found to be able to survive 1000 cycles when the intermediate layer was used, but reduced laminar cracking was observed in the specimen with the primer. It is suggested that the sputtered YZS primer-induced properties are due to (1) more effective wetting and adherence of the plasma-sprayed YZS particles to the primer, and (2) the primer's retardation of impinging, molten plasma sprayed particles solidification rates, which result in a less detrimental residual stress distribution.

  17. Caracterisation of Titanium Nitride Layers Deposited by Reactive Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Roşu, Radu Alexandru; Şerban, Viorel-Aurel; Bucur, Alexandra Ioana; Popescu, Mihaela; Uţu, Dragoş

    2011-01-01

    Forming and cutting tools are subjected to the intense wear solicitations. Usually, they are either subject to superficial heat treatments or are covered with various materials with high mechanical properties. In recent years, thermal spraying is used increasingly in engineering area because of the large range of materials that can be used for the coatings. Titanium nitride is a ceramic material with high hardness which is used to cover the cutting tools increasing their lifetime. The paper presents the results obtained after deposition of titanium nitride layers by reactive plasma spraying (RPS). As deposition material was used titanium powder and as substratum was used titanium alloy (Ti6Al4V). Macroscopic and microscopic (scanning electron microscopy) images of the deposited layers and the X ray diffraction of the coatings are presented. Demonstration program with layers deposited with thickness between 68,5 and 81,4 μm has been achieved and presented.

  18. Advancement in Preparation of Hydroxyapatite/bioglass Graded Coatings by Electrophoretic Deposition

    NASA Astrophysics Data System (ADS)

    Yao, Liang; Chen, Chuanzhong; Wang, Diangang; Bao, Quanhe; Ma, Jie

    Electrophoretic deposition is a good method in the preparation of hydroxyapatite/bioglass graded coatings. Its processing parameters are easy to be operated. As it is nonbeeline process, it can be used in the deposition of complex shape and porous surface. This paper reviewed the advancement of the graded coatings in recent years, concluded the principles, characters, steps of electrophoretic deposition of bioceramic coatings and analyzed influencing factors in detail, such as granularity of suspension, aging of suspension, dispersion media, PH of suspension, electricity, voltage, deposition time, pretreatment of substrate and sintering. The foreground of hydroxyapatite/bioglass graded coatings is expected.

  19. Anisotropic resistivity in plasma-sprayed silicon thick films

    NASA Astrophysics Data System (ADS)

    Kharas, Boris Dave; Sampath, Sanjay; Gambino, Richard J.

    2005-05-01

    Silicon thick films deposited by thermal plasma spray are of interest as inexpensive electronic materials for conformal meso-scale electronics applications. In addition they also serve as a model system for the investigation of electrical properties of coatings with layered anisotropy. In this study impedance spectroscopy was used to measure the complex resistivity of free-standing 64μm-thick polycrystalline silicon films deposited by thermal plasma spraying in an atmospheric ambient. Impedance spectroscopy measurements were taken in the through-thickness (across-splat) and edge-to-edge (in-splat) directions and revealed a resistivity difference of approximately 7.5±0.23 between the two directions. The complex resistivity results are explained on the basis of a brick-layer type model, associated with the layered splat microstructure obtained from cross-sectional transmission electron microscope imaging of the films. In addition a circuit-based model made up of parallel, resistor-capacitor elements in series, and Cole-Cole and Davidson-Cole impedance functions were used to fit the impedance data to extract material parameters and contributions from the grains and splat boundaries. Furthermore, thermal processing and phosphorus doping is shown to lead to higher and lower resistivity, respectively, in the films.

  20. Activity of vancomycin release from bioinspired coatings of hydroxyapatite or TiO2 nanotubes.

    PubMed

    Ionita, Daniela; Bajenaru-Georgescu, Daniela; Totea, Georgeta; Mazare, Anca; Schmuki, Patrik; Demetrescu, Ioana

    2017-01-30

    Herein we investigate the efficiency of various biomimetic coatings for localized drug delivery, using vancomycin as key therapeutic drug, which is a widely used antibiotic for the treatment of strong infections caused by positive Gram bacteria. We evaluate classical hydroxyapatite and biomimetic hydroxyapatite-collagen coatings obtained by electrochemical deposition as well as TiO2 nanotubes arrays obtained by electrochemical anodization. Surface morphology, compositional and structural data confirm the incorporation of vancomycin into the layers and drug release profiles for vancomycin evaluate their release ability. Namely, hydroxyapatite coatings lead to a ≈92% vancomycin release after 30h and hydroxyapatite-collagen to 85%, while the TiO2 nanotubes layers lead to 78% release. The antibacterial effect of such drug loaded coatings is evaluated against S. aureus (Gram-positive bacteria). Our study shows that the vancomycin incorporated hydroxyapatite coatings lead to a faster release, while the nanotubular coatings may lead to longer time release and additionally both types of coatings ensure a good antibacterial inhibition.

  1. An improved biofunction of titanium for keratoprosthesis by hydroxyapatite-coating.

    PubMed

    Dong, Ying; Yang, Jingxin; Wang, Liqiang; Ma, Xiao; Huang, Yifei; Qiu, Zhiye; Cui, Fuzhai

    2014-03-01

    Titanium framework keratoprosthesis has been commonly used in the severe corneal blindness, but the tissue melting occurred frequently around titanium. Since hydroxyapatite has been approved to possess a good tissue integration characteristic, nanostructured hydroxyapatite was coated on the surface of titanium through the aerosol deposition method. In this study, nanostructured hydroxyapatite coating was characterized by X-ray diffraction, scanning electron microscopy, atomic force microscopy, and auger electronic spectrometer. Biological evaluations were performed with rabbit cornea fibroblast in vitro and an animal model in vivo. The outcomes showed the coating had a grain-like surface topography and a good atomic mixed area with substrate. The rabbit cornea fibroblasts appeared a good adhesion on the surface of nanostructured hydroxyapatite in vitro. In the animal model, nanostructured hydroxyapatite-titanium implants were stably retained in the rabbit cornea, and by contrast, the corneal stroma became thinner anterior to the implants in the control. Therefore, our findings proved that nanostructured hydroxyapatite-titanium could not only provide an improved bond for substrate but also enhance the tissue integration with implants in host. As a promising material, nanostructured hydroxyapatite-titanium-based keratoprosthesis prepared by the aerosol deposition method could be utilized for the corneal blindness treatment.

  2. Automatic targeting of plasma spray gun

    DOEpatents

    Abbatiello, Leonard A.; Neal, Richard E.

    1978-01-01

    A means for monitoring the material portion in the flame of a plasma spray gun during spraying operations is provided. A collimated detector, sensitive to certain wavelengths of light emission, is used to locate the centroid of the material with each pass of the gun. The response from the detector is then relayed to the gun controller to be used to automatically realign the gun.

  3. T55-L-712 turbine engine compressor housing refurbishment-plasma spray project

    NASA Technical Reports Server (NTRS)

    Leissler, George W.; Yuhas, John S.

    1988-01-01

    A study was conducted to assess the feasibility of reclaiming T55-L-712 turbine engine compressor housings with an 88 wt percent aluminum to 12 wt percent silicon alloy applied by a plasma spray process. Tensile strength testing was conducted on as-sprayed and thermally cycled test specimens which were plasma sprayed with 0.020 to 0.100 in. coating thicknesses. Satisfactory tensile strength values were observed in the as-sprayed tensile specimens. There was essentially no decrease in tensile strength after thermally cycling the tensile specimens. Furthermore, compressor housings were plasma sprayed and thermally cycled in a 150-hr engine test and a 200-hr actual flight test during which the turbine engine was operated at a variety of loads, speeds and torques. The plasma sprayed coating system showed no evidence of degradation or delamination from the compressor housings. As a result of these tests, a procedure was designed and developed for the application of an aluminum-silicon alloy in order to reclaim T55-L-712 turbine engine compressor housings.

  4. Fabrication and Microstructure of Hydroxyapatite Coatings on Zirconia by Room Temperature Spray Process.

    PubMed

    Seo, Dong Seok; Chae, Hak Cheol; Lee, Jong Kook

    2015-08-01

    Hydroxyapatite coatings were fabricated on zirconia substrates by a room temperature spray process and were investigated with regards to their microstructure, composition and dissolution in water. An initial hydroxyapatite powder was prepared by heat treatment of bovine-bone derived powder at 1100 °C for 2 h, while dense zirconia substrates were fabricated by pressing 3Y-TZP powder and sintering it at 1350 °C for 2 h. Room temperature spray coating was performed using a slit nozzle in a low pressure-chamber with a controlled coating time. The phase composition of the resultant hydroxyapatite coatings was similar to that of the starting powder, however, the grain size of the hydroxyapatite particles was reduced to about 100 nm due to their formation by particle impaction and fracture. All areas of the coating had a similar morphology, consisting of reticulated structure with a high surface roughness. The hydroxyapatite coating layer exhibited biostability in a stimulated body fluid, with no severe dissolution being observed during in vitro experimentation.

  5. Plasma spray nozzle with low overspray and collimated flow

    NASA Technical Reports Server (NTRS)

    Beason, Jr., George P. (Inventor); McKechnie, Timothy N. (Inventor); Power, Christopher A. (Inventor)

    1996-01-01

    An improved nozzle for reducing overspray in high temperature supersonic plasma spray devices comprises a body defining an internal passageway having an upstream end and a downstream end through which a selected plasma gas is directed. The nozzle passageway has a generally converging/diverging Laval shape with its upstream end converging to a throat section and its downstream end diverging from the throat section. The upstream end of the passageway is configured to accommodate a high current cathode for producing an electrical arc in the passageway to heat and ionize the gas flow to plasma form as it moves along the passageway. The downstream end of the nozzle is uniquely configured through the methodology of this invention to have a contoured bell-shape that diverges from the throat to the exit of the nozzle. Coating material in powder form is injected into the plasma flow in the region of the bell-shaped downstream end of the nozzle and the powder particles become entrained in the flow. The unique bell shape of the nozzle downstream end produces a plasma spray that is ideally expanded at the nozzle exit and thus virtually free of shock phenomena, and that is highly collimated so as to exhibit significantly reduced fanning and diffusion between the nozzle and the target. The overall result is a significant reduction in the amount of material escaping from the plasma stream in the form of overspray and a corresponding improvement in the cost of the coating operation and in the quality and integrity of the coating itself.

  6. Characterization and In Vitro Corrosion Investigations of Thermal Sprayed Hydroxyapatite and Hydroxyapatite-Titania Coatings on Ti Alloy

    NASA Astrophysics Data System (ADS)

    Sarao, Tejinder Pal Singh; Sidhu, Hazoor Singh; Singh, Harpreet

    2012-11-01

    In the current investigation, hydroxyapatite (HA) powder was mixed with titania (TiO2) in 50:50 wt pct for depositing composite coatings on a Ti-alloy substrate using a thermal-spray coating technique. The coatings were characterized by X-ray diffraction (XRD) and scanning electron microscopy (SEM)/energy-dispersive X-ray spectroscopy (EDS) analyses. The corrosion behavior of the coatings was studied by electrochemical corrosion testing in simulated human body fluid. After the corrosion testing, the samples were analyzed by XRD and SEM/EDS analyses. HA and TiO2 (rutile) were the main phases observed in the developed coatings. Bulk HA coating was amorphous; however, the addition of TiO2 effectively improved the crystallinity of HA in HA-TiO2 coating. The SEM analysis confirmed the formation of a well-formed HA-TiO2 composite coating. HA coating exhibited higher bond strength (67.8 MPa) compared with HA-TiO2 composite coating (37.6 MPa). The electrochemical study showed a significant improvement in the corrosion resistance of the Ti alloy after the deposition of the coatings.

  7. Plasma Spray-PVD: A New Thermal Spray Process to Deposit Out of the Vapor Phase

    NASA Astrophysics Data System (ADS)

    von Niessen, Konstantin; Gindrat, Malko

    2011-06-01

    Plasma spray-physical vapor deposition (PS-PVD) is a low pressure plasma spray technology recently developed by Sulzer Metco AG (Switzerland). Even though it is a thermal spray process, it can deposit coatings out of the vapor phase. The basis of PS-PVD is the low pressure plasma spraying (LPPS) technology that has been well established in industry for several years. In comparison to conventional vacuum plasma spraying (VPS) or low pressure plasma spraying (LPPS), the new proposed process uses a high energy plasma gun operated at a reduced work pressure of 0.1 kPa (1 mbar). Owing to the high energy plasma and further reduced work pressure, PS-PVD is able to deposit a coating not only by melting the feed stock material which builds up a layer from liquid splats but also by vaporizing the injected material. Therefore, the PS-PVD process fills the gap between the conventional physical vapor deposition (PVD) technologies and standard thermal spray processes. The possibility to vaporize feedstock material and to produce layers out of the vapor phase results in new and unique coating microstructures. The properties of such coatings are superior to those of thermal spray and electron beam-physical vapor deposition (EB-PVD) coatings. In contrast to EB-PVD, PS-PVD incorporates the vaporized coating material into a supersonic plasma plume. Owing to the forced gas stream of the plasma jet, complex shaped parts such as multi-airfoil turbine vanes can be coated with columnar thermal barrier coatings using PS-PVD. Even shadowed areas and areas which are not in the line of sight of the coating source can be coated homogeneously. This article reports on the progress made by Sulzer Metco in developing a thermal spray process to produce coatings out of the vapor phase. Columnar thermal barrier coatings made of Yttria-stabilized Zircona (YSZ) are optimized to serve in a turbine engine. This process includes not only preferable coating properties such as strain tolerance and erosion

  8. Influence of Glass Content on Damping Properties of Plasma-Sprayed Mixtures of Zirconia and Glass

    NASA Astrophysics Data System (ADS)

    Torvik, P. J.; Henderson, J. P.

    2012-07-01

    The addition by vacuum infiltration of small quantities of a polymer has been found to increase significantly the ability of a plasma-sprayed coating to dissipate vibratory energy at temperatures in the glassy-rubbery transition range of the polymer. As vitreous enamels and glasses undergo a glassy transition, but at much higher temperatures, the addition of a small amount of glass to a ceramic has the potential of providing high damping at such temperatures. Mixtures of yttria-stabilized zirconia (YSZ) and a glass frit were plasma sprayed on specimens with bond coats. Measures of system response (resonant frequencies and loss factors) were extracted from frequency responses to excitations of cantilever beam specimens over a range of excitation amplitudes. Comparisons of values determined before and after coating were used to determine the damping properties of the coatings alone as functions of strain, at temperatures of special interest. Emphasis was given to identifying the lowest level of glass giving significantly more damping than that of the plasma-sprayed ceramic alone. Coatings with weight fractions of 5, 2, 1, ½, and 0% glass were tested. The inclusion of glass at all weight fractions considered was found to yield significant increases in both the stiffness and dissipation of the coatings.

  9. Electroplasma coatings based on silicon-containing hydroxyapatite: Technology and properties

    NASA Astrophysics Data System (ADS)

    Lyasnikova, A. V.; Markelova, O. A.

    2016-09-01

    IR analysis and the plasma deposition of silicon-containing hydroxyapatite powder have been carried out. It has been shown that the coating exhibits developed morphology and consists of molten powder (including nanosize) particles uniformly distributed over the entire surface. The adhesion characteristics have been calculated and scanning electron microscope images of the resultant coating have been analyzed.

  10. Novel Hydroxyapatite Coatings for the Conservation of Marble and Limestone

    NASA Astrophysics Data System (ADS)

    Naidu, Sonia

    Marble and limestone are calcite-based materials used in the construction of various structures, many of which have significant artistic and architectural value. Unfortunately, due to calcite's high dissolution rate, these stones are susceptible to chemically-induced weathering in nature. Limestone, due to its inherent porosity, also faces other environmental weathering processes that cause weakening from disintegration at grain boundaries. The treatments presently available are all deficient in one way or another. The aim of this work is to examine the feasibility of using hydroxyapatite (HAP) as a novel protective coating for marble and limestone, with two goals: i) to reduce acid corrosion of marble and ii) to consolidate physically weathered limestone. The motivation for using HAP is its low dissolution rate and structural compatibility with calcite. Mild, wet chemical synthesis routes, in which inorganic phosphate-based solutions were reacted with marble and limestone, alone and with other precursors, were used to produce HAP films. Film nucleation, growth and phase evolution were studied on marble to understand film formation and determine the optimal synthesis route. An acid resistance test was developed to investigate the attack mechanism on marble and quantify the efficacy of HAP-based coatings. Film nucleation and growth were dependent on substrate surface roughness and increased with calcium and carbonate salt additions during synthesis. Acid attack on marble occurred via simultaneous dissolution at grain boundaries, twin boundaries and grain surfaces. HAP provided intermediate protection against acid attack, when compared to two conventional treatments. Its ability to protect the stone from acid was not as significant as predicted from dissolution kinetics and this was attributed to incomplete coverage and residual porosity within the film, arising from its flake-like crystal growth habit, which enabled acid to access the underlying substrate. The

  11. Modeling Plasma-Particle Interaction in Multi-Arc Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Bobzin, K.; Öte, M.

    2017-02-01

    The properties of plasma-sprayed coatings are controlled by the heat, momentum, and mass transfer between individual particles and the plasma jet. The particle behavior in conventional single-arc plasma spraying has been the subject of intensive numerical research, whereas multi-arc plasma spraying has not yet received the same attention. We propose herein a numerical model to serve as a scientific tool to investigate particle behavior in multi-arc plasma spraying. In the Lagrangian description of particles in the model, the mathematical formulations describing the heat, momentum, and mass transfer are of great importance for good predictive power, so such formulations proposed by different authors were compared critically, revealing that different mathematical formulations lead to significantly different results. The accuracy of the different formulations was evaluated based on theoretical considerations, and those found to be more accurate were implemented in the final model. Furthermore, a mathematical formulation is proposed to enable simplified calculation of partial particle melting and resolidification.

  12. Modeling Plasma-Particle Interaction in Multi-Arc Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Bobzin, K.; Öte, M.

    2017-01-01

    The properties of plasma-sprayed coatings are controlled by the heat, momentum, and mass transfer between individual particles and the plasma jet. The particle behavior in conventional single-arc plasma spraying has been the subject of intensive numerical research, whereas multi-arc plasma spraying has not yet received the same attention. We propose herein a numerical model to serve as a scientific tool to investigate particle behavior in multi-arc plasma spraying. In the Lagrangian description of particles in the model, the mathematical formulations describing the heat, momentum, and mass transfer are of great importance for good predictive power, so such formulations proposed by different authors were compared critically, revealing that different mathematical formulations lead to significantly different results. The accuracy of the different formulations was evaluated based on theoretical considerations, and those found to be more accurate were implemented in the final model. Furthermore, a mathematical formulation is proposed to enable simplified calculation of partial particle melting and resolidification.

  13. Fluor-hydroxyapatite sol-gel coating on titanium substrate for hard tissue implants.

    PubMed

    Kim, Hae-Won; Kim, Hyoun-Ee; Knowles, Jonathan C

    2004-08-01

    Hydroxyapatite (HA) and fluor-hydroxyapatite (FHA) films were deposited on a titanium substrate using a sol-gel technique. Different concentrations of F- were incorporated into the apatite structure during the sol preparation. Typical apatite structures were obtained for all coatings after dipping and subsequent heat treatment at 500 degrees C. The films obtained were uniform and dense, with a thickness of approximately 5 microm. The dissolution rate of the coating layer decreased with increasing F- incorporation within the apatite structure, which demonstrates the possibility of tailoring the solubility by a functional gradient coating of HA and FHA. The cell proliferation rate on the coating layer decreased slightly with increasing F- incorporation. The alkaline phosphatase (ALP) activity of the cells on all the HA and FHA coated samples showed much higher expression levels compared to pure Ti. This confirmed the improved activity of cell functions on the substrates with the sol-gel coating treatment.

  14. The use of a macroscopic formulation describing the effects of dynamic compaction and porosity on plasma sprayed copper

    SciTech Connect

    Arrigoni, M.; Boustie, M.; Bolis, C.; Berthe, L.; Barradas, S.; Jeandin, M.

    2008-04-15

    Coatings processed by thermal deposition techniques involve porosity. The Laser adhesion test developed for testing bond strength of a coating on its substrate requires a good knowledge of shock wave propagation in such media. Experiments carried out on plasma sprayed copper samples, about 14% porous, with velocity interferometer system for any reflector measurements display the discrepancy of previously used models. Hence, a one-dimensional formulation of the compaction process, based on a simple P-{alpha} model, is proposed to improve the correlation between experimental and computed data signals obtained on a plasma sprayed copper under dynamic loading. Besides, this improvement allows the estimation of the bond strength of a plasma sprayed copper on aluminum substrate.

  15. Carbon Nanotubes Reinforced Al-11 wt% Si Alloy via Plasma Spray

    NASA Astrophysics Data System (ADS)

    Moosa, Ahmed A.; Mohamed, Mohamed I.; Ismael, Mustafa K.

    2015-10-01

    In this work, multi-walled carbon nanotubes (MWCNTs) with different portions (0.5, l, 2, 4) wt% were added to a gas atomized Al-ll wt% Si powder. The Al-ll wt% /MWCNTS nanocomposite powder was examined by FESEM, Raman spectroscopy, X-ray diffraction (XRD). Air plasma spraying (APS) was used to spray Al-ll wt% Si/MwCNTs nanocomposite powder on aluminum alloy AA6082-T6 substrates. Al-ll wt% Si/MWCNTs nanocomposite coating layer was examined using FESEM/EDS, Raman spectroscopy, XRD and HRTEM. SEM/EDS showed that Al4C3 is formed at the interface e between the coating layer and the substrate in Al-ll wt% Si/4 wt% MWCNTs plasma spray coating. The adhesion test showed good adhesion in the ranges 5-l5 MPa between the coating layer and the substrate. Microhardness test of the air plasma sprayed (APS) Al-ll wt% Si/MWNTs nanocomposite layer is increased with the MWCNTs wt%.

  16. Optimization of Plasma Spray Process Using Statistical Methods

    NASA Astrophysics Data System (ADS)

    Gao, F.; Huang, X.; Liu, R.; Yang, Q.

    2012-01-01

    The microstructure features of coatings produced by a plasma spray process are affected significantly by the process parameters such as powder size, spray gun nozzle size, total plasma gas flow, ratio of H2 + N2 over total gas flow, and so on. This article presents a study of the effects of these parameters on the microstructure (porosity, formation of crack, unmelted particle and oxide phase) of NiCrAlY coatings deposited by the Mettech Axial III™ System. A Taguchi array is used to design the spraying process parameters. The results of the microstructure evaluation are used to generate regression equations for the prediction of coating microstructure based on process parameters. The results predicted from the regression equations are in good agreement with the experimental results according to a confidence level of 0.95. Among the parameters examined, the powder size and the ratio of H2 + N2 over total gas flow rate are the most significant parameters affecting the occurrence of crack, porosity, unmelted particle and oxide. Within the range of the designed process parameters, lower powder size and higher ratio of H2 + N2 over total gas flow rate lead to less cracks, pores, unmelted particles but more oxides. Nozzle size has marginal influence on oxides which increase with nozzle size. Gas flow rate has no direct influence on any coating feature evaluated with the range of variation.

  17. Improvement of Plasma Spray Torch Stability by Controlling Pressure and Voltage Dynamic Coupling

    NASA Astrophysics Data System (ADS)

    Rat, V.; Coudert, J. F.

    2011-01-01

    The development of coating formation processes involving electric arcs depends on process stability and the capacity to ensure a constant reproducibility of coating properties. This is particularly important when considering suspension plasma spraying or solution precursor plasma spraying. Submicron particles closely follow plasma instabilities and have nonhomogeneous plasma treatment. Recently, it has been shown that arc voltage fluctuations in direct-current (dc) plasma torches, showing dominant fluctuation frequencies between 4 and 6 kHz, are linked to pressure oscillations in the cathode cavity of the plasma torch. In this study, first, a method to isolate the different oscillation modes in arc voltage and pressure signals using signal processing methods is presented. Second, correlations between the different modes of oscillations are analyzed following the plasma torch operating parameters. Lastly, it is shown that the use of an acoustic stub, mounted on the torch body, decreases the amplitude of arc voltage fluctuations and slightly increases the mean voltage.

  18. Nano-composite Si particle formation by plasma spraying for negative electrode of Li ion batteries

    NASA Astrophysics Data System (ADS)

    Kambara, M.; Kitayama, A.; Homma, K.; Hideshima, T.; Kaga, M.; Sheem, K.-Y.; Ishida, S.; Yoshida, T.

    2014-04-01

    Nano-composite silicon powders have been produced at a maximum process throughput of 6 g/min by plasma spraying with metallurgical grade silicon powder as raw material. The obtained powders are found to be fundamentally composed of crystalline silicon particles of 20-40 nm in diameter, and are coated with an ˜5-nm-thick amorphous carbonous layer when methane gas is additionally introduced during plasma spraying. The performance of half-cell batteries containing the powders as negative electrodes has shown that the capacity decay observed for the raw Si coarse particles is significantly improved by plasma treatment. The carbonous coating potentially contributes to an improvement in capacity retention, although coexisting SiC particles that inevitably form during high-temperature processing reduce the overall capacity.

  19. Preparation of hydroxyapatite-containing titania coating on titanium substrate by micro-arc oxidation

    SciTech Connect

    Ni Jiahua; Shi Yulong Yan Fengying; Chen Jianzhi; Wang Lei

    2008-01-08

    Hydroxyapatite-containing titania coatings on titanium substrates were formed by micro-arc oxidation (MAO) in electrolyte containing calcium acetate monohydrate (CH{sub 3}COO){sub 2}Ca.H{sub 2}O) and sodium phosphate monobasic dihydrate (NaH{sub 2}PO{sub 4}.2H{sub 2}O) using a pulse power supply. Scanning electron microscopy (SEM) with Energy dispersive X-ray spectrometer (EDX) and X-ray diffraction (XRD) were employed to characterize the microstructure, elemental composition and phase components of the coatings. The coatings were rough and porous, without apparent interface to the titanium substrates. All the oxidized coatings contained Ca and P as well as Ti and O, and the porous coatings were made up of anatase, rutile and hydroxyapatite. Such MAO films are expected to have significant applications as artificial bone joints and dental implants.

  20. [Preparation of hydroxyapatite coating in concentrated simulated body fluid by accelerated biomimetic synthesis].

    PubMed

    Li, Yadong; Liu, Jingxiao; Shi, Fei; Tang, Nailing; Yu, Ling

    2007-12-01

    In the present work, NiTi alloy substrates were activated by three different pretreatment processes. 5 X SBF1 and 5 X SBF2 concentrated simulated body fluids were prepared with citric acid buffer reagent, and then calcium phosphate coatings were formed quickly on NiTi alloy surface by accelerated biomimetic synthesis after pretreatment. The microstructure, composition and surface morphology of calcium phosphate coatings were studied. The results indicate that calcium phosphate coatings possess porous and net structure, which are composed of precipitated spherical particles with diameter less than 3 microm. The analysis of XRD shows that the main component of calcium phosphate coatings is hydroxyapatite, whereas the concentrated 5 x SBF simulated body fluid, which is in the absence of Mg2+ and HCO3- crystal growth inhibitors, apparently accelerates the growth rate of hydroxyapatite coatings.

  1. Atmospheric Plasma Spraying of High Melting Temperature Complex Perovskites for TBC Application

    NASA Astrophysics Data System (ADS)

    Jarligo, M. O.; Mack, D. E.; Mauer, G.; Vaßen, R.; Stöver, D.

    2010-01-01

    High melting materials have always been very attractive candidates for materials development in thermal barrier coating (TBC) applications. Among these materials, complex perovskites with Ba(Mg1/3Ta2/3)O3 and La(Al1/4Mg1/2T1/4)O3 compositions have been developed and deposited in TBC systems by atmospheric plasma spraying. Spray parameters were optimized and in-flight particle temperatures were recorded using Accuraspray-g3 and DPV 2000. Plasma sprayed coatings were found to undergo non-stoichiometric decomposition of components which could have contributed to early failure of the coatings. Particle temperature diagnostics suggest that gun power of ~15 kW or lower where majority of the particles have already solidified upon impact to the substrate could probably prevent the decomposition of phases. Additionally, it has been found that the morphology of the powder feedstock plays a critical role during atmospheric plasma spraying of complex perovskites.

  2. SEM and EDX studies of bioactive hydroxyapatite coatings on titanium implants.

    PubMed

    Ciobanu, Gabriela; Carja, Gabriela; Ciobanu, Octavian; Sandu, Ion; Sandu, Andrei

    2009-01-01

    This work presents a study on an alternative coating method based on biomimetic techniques which are designed to form a crystalline hydroxyapatite layer very similar to the process corresponding to the formation of natural bone. The HA formation on the surface of titanium alloy pretreated with NaOH solution is investigated. Two types of solutions such as supersaturated calcification solution (SCS) and modified SCS (M-SCS) were used to investigate bone-like apatite formation on alkali-treated titanium. The hydroxyapatite deposits are investigated by means of scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDX). The data suggest that the method utilized in this work can be successfully applied to obtain deposition of uniform coatings of crystalline hydroxyapatite on titanium substrates.

  3. Formation of Solution-derived Hydroxyapatite Coatings on Titanium Alloy in the Presence of Magnetron-sputtered Alumina Bond Coats.

    PubMed

    Zykova, Anna; Safonov, Vladimir; Yanovska, Anna; Sukhodub, Leonid; Rogovskaya, Renata; Smolik, Jerzy; Yakovin, Stas

    2015-01-01

    Hydroxyapatite Ca10(PO4)6(OH)2 (HAp) and calcium phosphate ceramic materials and coatings are widely used in medicine and dentistry because of their ability to enhance the tissue response to implant surfaces and promote bone ingrowth and osseoconduction processes. The deposition conditions have a great influence on the structure and biofunctionality of calcium phosphate coatings. Corrosion processes and poor adhesion to substrate material reduce the lifetime of implants with calcium phosphate coatings. The research has focused on the development of advanced methods to deposit double-layered ceramic oxide/calcium phosphate coatings by a hybrid technique of magnetron sputtering and thermal methods. The thermal method can promote the crystallization and the formation of HAp coatings on titanium alloy Ti6Al4V substrates at low temperature, based on the principle that the solubility of HAp in aqueous solutions decreases with increasing substrate temperature. By this method, hydroxyapatite directly coated the substrate without precipitation in the initial solution. Using a thermal substrate method, calcium phosphate coatings were prepared at substrate temperatures of 100-105 (o)C. The coated metallic implant surfaces with ceramic bond coats and calcium phosphate layers combine the excellent mechanical properties of metals with the chemical stability of ceramic materials. The corrosion test results show that the ceramic oxide (alumina) coatings and the double-layered alumina-calcium phosphate coatings improve the corrosion resistance compared with uncoated Ti6Al4V and single-layered Ti6Al4V/calcium phosphate substrates. In addition, the double-layered alumina/hydroxyapatite coatings demonstrate the best biocompatibility during in vitro tests.

  4. Formation of Solution-derived Hydroxyapatite Coatings on Titanium Alloy in the Presence of Magnetron-sputtered Alumina Bond Coats

    PubMed Central

    Zykova, Anna; Safonov, Vladimir; Yanovska, Anna; Sukhodub, Leonid; Rogovskaya, Renata; Smolik, Jerzy; Yakovin, Stas

    2015-01-01

    Hydroxyapatite Ca10(PO4)6(OH)2 (HAp) and calcium phosphate ceramic materials and coatings are widely used in medicine and dentistry because of their ability to enhance the tissue response to implant surfaces and promote bone ingrowth and osseoconduction processes. The deposition conditions have a great influence on the structure and biofunctionality of calcium phosphate coatings. Corrosion processes and poor adhesion to substrate material reduce the lifetime of implants with calcium phosphate coatings. The research has focused on the development of advanced methods to deposit double-layered ceramic oxide/calcium phosphate coatings by a hybrid technique of magnetron sputtering and thermal methods. The thermal method can promote the crystallization and the formation of HAp coatings on titanium alloy Ti6Al4V substrates at low temperature, based on the principle that the solubility of HAp in aqueous solutions decreases with increasing substrate temperature. By this method, hydroxyapatite directly coated the substrate without precipitation in the initial solution. Using a thermal substrate method, calcium phosphate coatings were prepared at substrate temperatures of 100-105 oC. The coated metallic implant surfaces with ceramic bond coats and calcium phosphate layers combine the excellent mechanical properties of metals with the chemical stability of ceramic materials. The corrosion test results show that the ceramic oxide (alumina) coatings and the double-layered alumina-calcium phosphate coatings improve the corrosion resistance compared with uncoated Ti6Al4V and single-layered Ti6Al4V/calcium phosphate substrates. In addition, the double-layered alumina/hydroxyapatite coatings demonstrate the best biocompatibility during in vitro tests. PMID:25893018

  5. Poly(vinyl alcohol) hydrogel coatings with tunable surface exposure of hydroxyapatite.

    PubMed

    Moreau, David; Villain, Arthur; Ku, David N; Corté, Laurent

    2014-01-01

    Insufficient bone anchoring is a major limitation of artificial substitutes for connective osteoarticular tissues. The use of coatings containing osseoconductive ceramic particles is one of the actively explored strategies to improve osseointegration and strengthen the bone-implant interface for general tissue engineering. Our hypothesis is that hydroxyapatite (HA) particles can be coated robustly on specific assemblies of PVA hydrogel fibers for the potential anchoring of ligament replacements. A simple dip-coating method is described to produce composite coatings made of microscopic hydroxyapatite (HA) particles dispersed in a poly(vinyl alcohol) (PVA) matrix. The materials are compatible with the requirements for implant Good Manufacturing Practices. They are applied to coat bundles of PVA hydrogel fibers used for the development of ligament implants. By means of optical and electronic microscopy, we show that the coating thickness and surface state can be adjusted by varying the composition of the dipping solution. Quantitative analysis based on backscattered electron microscopy show that the exposure of HA at the coating surface can be tuned from 0 to over 55% by decreasing the weight ratio of PVA over HA from 0.4 to 0.1. Abrasion experiments simulating bone-implant contact illustrate how the coating cohesion and wear resistance increase by increasing the content of PVA relative to HA. Using pullout experiments, we find that these coatings adhere well to the fiber bundles and detach by propagation of a crack inside the coating. These results provide a guide to select coated implants for anchoring artificial ligaments.

  6. Concept for a beryllium divertor with in-situ plasma spray surface regeneration

    NASA Astrophysics Data System (ADS)

    Smith, M. F.; Watson, R. D.; McGrath, R. T.; Croessmann, C. D.; Whitley, J. B.; Causey, R. A.

    1990-04-01

    Two serious problems with the use of graphite tiles on the ITER divertor are the limited lifetime due to erosion and the difficulty of replacing broken tiles inside the machine. Beryllium is proposed as an alternative low-Z armor material because the plasma spray process can be used to make in-situ repairs of eroded or damaged surfaces. Recent advances in plasma spray technology have produced beryllium coatings of 98% density with a 95% deposition efficiency and strong adhesion to the substrate. With existing technology, the entire active region of the ITER divertor surface could be coated with 2 mm of beryllium in less than 15 h using four small plasma spray guns. Beryllium also has other potential advantages over graphite, e.g., efficient gettering of oxygen, ten times less tritium inventory, reduced problems of transient fueling from D/T exchange and release, no runaway erosion cascades from self-sputtering, better adhesion of redeposited material, as well as higher strength, ductility, and fracture toughness than graphite. A 2-D finite element stress analysis was performed on a 3 mm thick Be tile brazed to an OFHC soft-copper saddle block, which was brazed to a high-strength copper tube. Peak stresses remained 50% below the ultimate strength for both brazing and in-service thermal stresses.

  7. Predicting radiative transport properties of plasma sprayed porous ceramics

    NASA Astrophysics Data System (ADS)

    Wang, B. X.; Zhao, C. Y.

    2016-03-01

    The typical yttria-stabilized zirconia material for making the thermal barrier coatings (TBCs) is intrinsically semitransparent to thermal radiation, and the unique disordered microstructures in TBCs make them surprisingly highly scattering. To quantitatively understand the influence of disordered microstructures, this paper presents a quantitative prediction on the radiative properties, especially the transport scattering coefficient of plasma sprayed TBC based on microstructure analysis and rigorous electromagnetic theory. The impact of the porosity, shape, size, and orientation of different types of voids on transport scattering coefficient is comprehensively investigated under the discrete dipole approximation. An inverse model integrating these factors together is then proposed to quantitatively connect transport scattering coefficient with microstructural information, which is also validated by available experimental data. Afterwards, an optimization procedure is carried out based on this model to obtain the optimal size and orientation distribution of the microscale voids to achieve the maximal radiation insulation performance at different operating temperatures, providing guidelines for practical coating design and fabrication. This work suggests that the current model is effective and also efficient for connecting scattering properties to microstructures and can be implemented as a quantitative tool for further studies like non-destructive infrared imaging as well as micro/nanoscale thermal design of TBCs.

  8. Poly(L-lactic acid)/hydroxyapatite/collagen composite coatings on AZ31 magnesium alloy for biomedical application.

    PubMed

    Wang, Zhen-Lin; Yan, Yu-Hua; Wan, Tao; Yang, Hui

    2013-10-01

    Surface modification of biomedical magnesium alloy using composite coating shows an attemptable approach for the development of Mg-based biomaterials with excellent cytocompatibility. Hydroxyapatite/collagen composite was preliminarily fabricated by biomineralization, the bioactive poly(l-lactic acid)/hydroxyapatite/collagen composite coatings were spin coated on AZ31 magnesium alloy using poly(l-lactic acid) solution mixed with hydroxyapatite/collagen particles, and the resultant materials and coatings were characterized in structure and related properties; furthermore, the in vitro degradation behavior of modified magnesium alloy in 1.5-fold Hank's solution was investigated. The results show that hydroxyapatite/collagen composite achieved chemical bonding between hydroxyapatite and collagen similar to natural bone; composite coatings on AZ31 magnesium alloy retained the bioactive functional groups of the componential materials and improved the corrosion resistance of Mg alloy; the mass fraction of hydroxyapatite/collagen particles incorporated into the composite affected the porous structure, interfacial adhesion and thus the corrosion resistance of the composite coating due to phase separation as well as volume concentration effects of polymer solution. Composite coatings suppressed the sharp rising of pH value and the released Mg(2+) from substrate to extensive degree, and the degradation behavior of the modified magnesium alloy was supposed to be correlated to microstructure of the coating as well as the synergistic reactions among alkaline- and acidic-degraded products.

  9. Microstructural characteristics of plasma sprayed nanostructured partially stabilized zirconia

    NASA Astrophysics Data System (ADS)

    Lima, Rogerio Soares

    Thermal barrier coatings have been extensively applied in the aerospace industry in turbines and rocket engines as an insulation system. Partially stabilized zirconia, due to its high thermal stability and low thermal conductivity at high temperatures has been traditionally employed as the ceramic element of the thermal barrier coating system. Different approaches have been taken in order to improve the performance of these coatings. Nanostructured materials are promising an interesting future in the beginning of the 21st century. Due to its enhanced strain to failure and superplasticity new applications may be accomplished or the limits of materials utilization may be placed at higher levels. Single nanostructured particles can not be thermal sprayed by conventional thermal spray equipment. Due to its low mass, they would be deviated to the periphery of the thermal spray jet. To overcome this characteristic, single nanostructured particles were successively agglomerated into large microscopic particles, with particle size distribution similar to the conventional feedstocks for thermal spray equipment. Agglomerated nanostructured particles of partially stabilized zirconia were plasma sprayed in air with different spray parameters. According to traditional thermal spray procedure, the feedstock has to be melted in the thermal spray jet in order to achieve the necessary conditions for adhesion and cohesion on the substrate. Due to the nature of the nanostructured particles, a new step has to be taken in the thermal spray processing; particle melting has to be avoided in order to preserve the feedstock nanostructure in the coating overall microstructure. In this work, the adhesion/cohesion system of nanostructured coatings is investigated and clarified. A percentage of molten particles will retain and hold the non-molten agglomerated nanostructured particles in the coating overall microstructure. Controlling the spray parameters it was possible to produce coatings

  10. Antimicrobial and osteogenic properties of a hydrophilic-modified nanoscale hydroxyapatite coating on titanium.

    PubMed

    Murakami, Asuka; Arimoto, Takafumi; Suzuki, Dai; Iwai-Yoshida, Misato; Otsuka, Fukunaga; Shibata, Yo; Igarashi, Takeshi; Kamijo, Ryutaro; Miyazaki, Takashi

    2012-04-01

    Hydroxyapatite (HA)-coated titanium (Ti) is commonly used for implantable medical devices. This study examined in vitro osteoblast gene expression and antimicrobial activity against early and late colonizers of supra-gingival plaque on nanoscale HA-coated Ti prepared by discharge in a physiological buffered solution. The HA-coated Ti surface showed super-hydrophilicity, whereas the densely sintered HA and Ti surfaces alone showed lower hydrophilicity. The sintered HA and HA-coated Ti surfaces enhanced osteoblast phenotypes in comparison with the bare Ti surface. The HA-coated Ti enabled antimicrobial activity against early colonizers of supra-gingival plaques, namely Streptococcus mitis and Streptococcus gordonii. Such antimicrobial activity may be caused by the surface hydrophilicity, thereby leading to a repulsion force between the HA-coated Ti surface and the bacterial cell membranes. On the contrary, the sintered HA sample was susceptible to infection of microorganisms. Thus, hydrophilic-modified HA-coated Ti may have potential for use in implantable medical devices. From the Clinical Editor: This study establishes that Hydroxyapatite (HA)-coated titanium (Ti) surface of implanted devices may result in an optimal microenvironment to control and prevent infections and may have potential future clinical applications.

  11. Hydroxyapatite-anatase-carbon nanotube nanocomposite coatings fabricated by electrophoretic codeposition for biomedical applications.

    PubMed

    Zhang, Bokai; Kwok, Chi Tat

    2011-10-01

    In order to eliminate micro-cracks in the monolithic hydroxyapatite (HA) and composite hydroxyapatite/carbon nanotube (HA/CNT) coatings, novel HA/TiO(2)/CNT nanocomposite coatings on Ti6Al4V were attempted to fabricate by a single-step electrophoretic codeposition process for biomedical applications. The electrophoretically deposited layers with difference contents of HA, TiO(2) (anatase) and CNT nanoparticles were sintered at 800°C for densification with thickness of about 7-10 μm. A dense and crack-free coating was achieved with constituents of 85 wt% HA, 10 wt% TiO(2) and 5 wt% CNT. Open-circuit potential measurements and cyclic potentiodynamic polarization tests were used to investigate the electrochemical corrosion behavior of the coatings in vitro conditions (Hanks' solution at 37°C). The HA/TiO(2)/CNT coatings possess higher corrosion resistance than that of the Ti6Al4V substrate as reflected by nobler open circuit potential and lower corrosion current density. In addition, the surface hardness and adhesion strength of the HA/TiO(2)/CNT coatings are higher than that of the monolithic HA and HA/CNT coatings without compromising their apatite forming ability. The enhanced properties were attributed to the nanostructure of the coatings with the appropriate TiO(2) and CNT contents for eliminating micro-cracks and micro-pores.

  12. Synthesis and properties of hydroxyapatite-containing coating on AZ31 magnesium alloy by micro-arc oxidation

    NASA Astrophysics Data System (ADS)

    Tang, Hui; Han, Yu; Wu, Tao; Tao, Wei; Jian, Xian; Wu, Yunfeng; Xu, Fangjun

    2017-04-01

    In this study, hydroxyapatite-containing coatings were prepared by microarc oxidation on AZ31 magnesium alloy surface to improve its biodegradation performance. Five applied voltages were chosen to prepare the MAO coatings. The results demonstrate that the number of micropores in the films increases but their dimensions decrease after higher voltage is applied. As the surface roughness of the MAO coatings increases with the applied voltage, the wettability of the coatings improves continuously. The MAO coatings were mainly composed of magnesium oxide (MgO) and hydroxyapatite. The amount of hydroxyapatite phase increased with increasing voltage that was applied. The bonding strength became slightly weaker after a higher voltage was applied. But the bonding strengths of all the coatings were consistently higher than 37 MPa, which met the requirement of implant biomaterials. All coatings exhibited higher corrosion resistances and lower hydrogen evolution rate than the bare AZ31 Mg substrate, implying that the degradation rate of the AZ31 Mg alloy was enhanced by the hydroxyapatite-containing coatings. The results indicate that the present treatment of applying hydroxyapatite-containing coatings is a promising technique for the degradable Mg-based biomaterials for orthopedic applications.

  13. Electrophoretic deposition of graphene oxide reinforced chitosan-hydroxyapatite nanocomposite coatings on Ti substrate.

    PubMed

    Shi, Y Y; Li, M; Liu, Q; Jia, Z J; Xu, X C; Cheng, Y; Zheng, Y F

    2016-03-01

    Electrophoretic deposition (EPD) is a facile and feasible technique to prepare functional nanocomposite coatings for application in orthopedic-related implants. In this work, a ternary graphene oxide-chitosan-hydroxyapatite (GO-CS-HA) composite coating on Ti substrate was successfully fabricated by EPD. Coating microstructure and morphologies were investigated by scanning electron microscopy, contact angle test, Raman spectroscopy, Fourier transform infrared spectroscopy and thermogravimetric analysis. It was found GO-CS surface were uniformly decorated by HA nanoparticles. The potentiodynamic polarization test in simulated body fluid indicated that the GO-CS-HA coatings could provide effective protection of Ti substrate from corrosion. This ternary composite coating also exhibited good biocompatibility during incubation with MG63 cells. In addition, the nanocomposite coatings could decrease the attachment of Staphylococcus aureus.

  14. Microwave-induced biomimetic approach for hydroxyapatite coatings of chitosan scaffolds.

    PubMed

    Kaynak Bayrak, Gökçe; Demirtaş, T Tolga; Gümüşderelioğlu, Menemşe

    2017-02-10

    Simulated body fluid (SBF) can form calcium phosphates on osteoinductive materials, so it is widely used for coating of bone scaffolds to mimic natural extracellular matrix (ECM). However, difficulties of bulk coating in 3D scaffolds and the necessity of long process times are the common problems for coating with SBF. In the present study, a microwave-assisted process was developed for rapid and internal coating of chitosan scaffolds. The scaffolds were fabricated as superporous hydrogel (SPH) by combining microwave irradiation and gas foaming methods. Then, they were immersed into 10x  SBF-like solution and homogenous bone-like hydroxyapatite (HA) coating was achieved by microwave treatment at 600W without the need of any nucleating agent. Cell culture studies with MC3T3-E1 preosteoblasts showed that microwave-assisted biomimetic HA coating process could be evaluated as an efficient and rapid method to obtain composite scaffolds for bone tissue engineering.

  15. Strontium-substituted hydroxyapatite coatings deposited via a co-deposition sputter technique.

    PubMed

    Boyd, A R; Rutledge, L; Randolph, L D; Meenan, B J

    2015-01-01

    The bioactivity of hydroxyapatite (HA) coatings can be modified by the addition of different ions, such as silicon (Si), lithium (Li), magnesium (Mg), zinc (Zn) or strontium (Sr) into the HA lattice. Of the ions listed here, strontium substituted hydroxyapatite (SrHA) coatings have received a lot of interest recently as Sr has been shown to promote osteoblast proliferation and differentiation, and reduce osteoclast activity. In this study, SrHA coatings were deposited onto titanium substrates using radio frequency (RF) magnetron co-sputtering (and compared to those surfaces deposited from HA alone). FTIR, XPS, XRD, and SEM techniques were used to analyse the different coatings produced, whereby different combinations of pure HA and 13% Sr-substituted HA targets were investigated. The results highlight that Sr could be successfully incorporated into the HA lattice to form SrHA coatings. It was observed that as the number of SrHA sputtering targets in the study were increased (increasing Sr content), the deposition rate decreased. It was also shown that as the Sr content of the coatings increased, so did the degree of preferred 002 orientation of the coating (along with obvious changes in the surface morphology). This study has shown that RF magnetron sputtering (specifically co-sputtering), offers an appropriate methodology to control the surface properties of Sr-substituted HA, such as the crystallinity, stoichiometry, phase purity and surface morphology.

  16. Numerical Study of Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Farrokhpanah, Amirsaman; Coyle, Thomas W.; Mostaghimi, Javad

    2017-01-01

    A numerical study of suspension plasma spraying is presented in the current work. The liquid suspension jet is replaced with a train of droplets containing the suspension particles injected into the plasma flow. Atomization, evaporation, and melting of different components are considered for droplets and particles as they travel toward the substrate. Effect of different parameters on particle conditions during flight and upon impact on the substrate is investigated. Initially, influence of the torch operating conditions such as inlet flow rate and power is studied. Additionally, effect of injector parameters like injection location, flow rate, and angle is examined. The model used in the current study takes high-temperature gradients and non-continuum effects into account. Moreover, the important effect of change in physical properties of suspension droplets as a result of evaporation is included in the model. These mainly include variations in heat transfer properties and viscosity. Utilizing this improved model, several test cases have been considered to better evaluate the effect of different parameters on the quality of particles during flight and upon impact on the substrate.

  17. Investigation of the interfacial condition between bioceramic coatings and metallic substrates using guided waves

    NASA Astrophysics Data System (ADS)

    Saffari, Nader; Ong, Chuon-Szen

    2001-04-01

    The work reported here is on the characterization of the interfacial properties between plasma-sprayed Hydroxyapatite coatings on titanium substrates as used in cement-less hip orthopaedic implants. The phase velocity dispersion for the first Rayleigh-type mode for the coating-substrate system has been shown to be sensitive to the interfacial stiffness. Different interfacial conditions between the coating and substrate have been obtained by cyclic loading of the specimens in a four-point bend fatigue machine. The measured interfacial stiffness is then correlated with the interfacial fracture strength obtained by standard destructive shear tests.

  18. Morphological and Mechanical Properties of Hydroxyapatite Bilayer Coatings Deposited on 316L SS by Sol-Gel Method

    NASA Astrophysics Data System (ADS)

    Sidane, Djahida; Khireddine, Hafit; Yala, Sabeha; Ziani, Salima; Bir, Fatima; Chicot, Didier

    2015-10-01

    The present paper reports on the influence of the addition of TiO2 and SiO2 oxides as sub-layer, on the morphological and mechanical properties of the hydroxyapatite (HAP) bioceramic coatings deposited on 316L stainless steel by sol-gel method in order to improve the properties of hydroxyapatite and expand its clinical application. The stability of the sols suspensions was evaluated by measuring the time dependence of the viscosity. Annealed properties of the coatings were analyzed by XPS, XRD, SEM, and EDS. The Vickers microhardness of the coatings is obtained under the same indentation load of 10 g. The hydroxyapatite coating deposited on the surface of the 316L SS substrate exhibits a porous carbonated apatitic structure. The results clearly demonstrate that HAP-TiO2 and HAP-SiO2 bilayer coatings where hydroxyapatite is deposited on the surface of TiO2- and SiO2-coated 316L SS substrate systems were highly homogeneous and uniform and show higher microhardness compared to HAP-coated 316L SS. A gap of nearly 10 pct is observed. The addition of TiO2 and SiO2 as sub-layer of a hydroxyapatite coating results in changes in surface morphology as well as an increase of the microhardness.

  19. The deposition of strontium and zinc Co-substituted hydroxyapatite coatings.

    PubMed

    Robinson, L; Salma-Ancane, K; Stipniece, L; Meenan, B J; Boyd, A R

    2017-03-01

    The in vitro and in vivo performance of hydroxyapatite (HAp) coatings can be modified by the addition of different trace ions, such as silicon (Si), lithium (Li), magnesium (Mg), zinc (Zn) or strontium (Sr) into the HAp lattice, to more closely mirror the complex chemistry of human bone. To date, most of the work in the literature has considered single ion-substituted materials and coatings, with limited reports on co-substituted calcium phosphate systems. The aim of this study was to investigate the potential of radio frequency magnetron sputtering to deposit Sr and Zn co-substituted HAp coatings using Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS). The FTIR and XPS results highlight that all of the Sr, Zn and Sr-Zn co-substituted surfaces produced are all dehydroxylated and are calcium deficient. All of the coatings contained HPO4(2-) groups, however; only the pure HAp coating and the Sr substituted HAp coating contained additional CO3(2-) groups. The XRD results highlight that none of the coatings produced in this study contain any other impurity CaP phases, showing peaks corresponding to that of ICDD file #01-072-1243 for HAp, albeit shifted to lower 2θ values due to the incorporation of Sr into the HAp lattice for Ca (in the Sr and Sr-Zn co-substituted surfaces only). Therefore, the results here clearly show that RF magnetron sputtering offers a simple means to deliver Sr and Zn co-substituted HAp coatings with enhanced surface properties. (a) XRD patterns for RF magnetron sputter deposited hydroxyapatite coatings and (b)-(d) for Sr, Zn and Sr-Zn co-substituted coatings, respectively. The XPS spectra in (b) confirms the presence of a HA sputter deposited coating as opposed to

  20. Poly(vinyl alcohol) hydrogel coatings with tunable surface exposure of hydroxyapatite

    PubMed Central

    Moreau, David; Villain, Arthur; Ku, David N; Corté, Laurent

    2014-01-01

    Insufficient bone anchoring is a major limitation of artificial substitutes for connective osteoarticular tissues. The use of coatings containing osseoconductive ceramic particles is one of the actively explored strategies to improve osseointegration and strengthen the bone-implant interface for general tissue engineering. Our hypothesis is that hydroxyapatite (HA) particles can be coated robustly on specific assemblies of PVA hydrogel fibers for the potential anchoring of ligament replacements. A simple dip-coating method is described to produce composite coatings made of microscopic hydroxyapatite (HA) particles dispersed in a poly(vinyl alcohol) (PVA) matrix. The materials are compatible with the requirements for implant Good Manufacturing Practices. They are applied to coat bundles of PVA hydrogel fibers used for the development of ligament implants. By means of optical and electronic microscopy, we show that the coating thickness and surface state can be adjusted by varying the composition of the dipping solution. Quantitative analysis based on backscattered electron microscopy show that the exposure of HA at the coating surface can be tuned from 0 to over 55% by decreasing the weight ratio of PVA over HA from 0.4 to 0.1. Abrasion experiments simulating bone-implant contact illustrate how the coating cohesion and wear resistance increase by increasing the content of PVA relative to HA. Using pullout experiments, we find that these coatings adhere well to the fiber bundles and detach by propagation of a crack inside the coating. These results provide a guide to select coated implants for anchoring artificial ligaments. PMID:25482413

  1. Characterization of hydroxyapatite coating by pulse laser deposition technique on stainless steel 316 L by varying laser energy

    NASA Astrophysics Data System (ADS)

    Khandelwal, Himanshu; Singh, Gurbhinder; Agrawal, Khelendra; Prakash, Satya; Agarwal, R. D.

    2013-01-01

    Hydroxyapatite is an attractive biomaterial mainly used in bone and tooth implants because it closely resembles human tooth and bone mineral and has proven to be biologically compatible with these tissues. In spite of this advantage of hydroxyapatite it has also certain limitation like inferior mechanical properties which do not make it suitable for long term load bearing applications; hence a lot of research is going on in the development of hydroxyapatite coating over various metallic implants. These metallic implants have good biocompatibility and mechanical properties. The aim of the present work is to deposit hydroxyapatite coating over stainless steel grade 316 L by pulse laser deposition technique by varying laser energy. To know the effect of this variation, the coatings were than characterized in detail by X-ray diffraction, finite emission-scanning electron microscope, atomic force microscope and energy dispersive X-ray spectroscopy.

  2. Local bisphosphonate release versus hydroxyapatite coating for stainless steel screw fixation in rat tibiae.

    PubMed

    Agholme, F; Andersson, T; Tengvall, P; Aspenberg, P

    2012-03-01

    Implant fixation in bone can be improved by a coating that delivers bisphosphonates locally, or by a hydroxyapatite (HA) coating. In this study, we compared these different types of coatings. For mechanical testing, 30 rats were assigned into three groups, and similar screws were implanted bilaterally in the proximal tibiae. The rats received screws that were either uncoated, coated with nano-crystalline hydroxyapatite or coated with a bisphosphonate releasing protein matrix. After 4 weeks, one screw was subjected to pull-out testing, and the contra-lateral one to torsion testing. For morphology, 30 rats were assigned to similar treatment groups, but received only one screw each. Bisphosphonates enhanced the pull-out force by 41% (P = 0.02) compared to controls, HA increased the pull-out force although not significantly. Conversely, HA increased the maximal torque by 64% (P = 0.02). Morphometry showed higher bone volume around bisphosphonate screws in comparison to HA-coated screws (P < 0.001) and controls (P < 0.001). The results suggest that bisphosphonates improve fixation by increasing the amount of surrounding bone, whereas HA mainly improves bone to implant attachment.

  3. Nanostructured glass–ceramic coatings for orthopaedic applications

    PubMed Central

    Wang, Guocheng; Lu, Zufu; Liu, Xuanyong; Zhou, Xiaming; Ding, Chuanxian; Zreiqat, Hala

    2011-01-01

    Glass–ceramics have attracted much attention in the biomedical field, as they provide great possibilities to manipulate their properties by post-treatments, including strength, degradation rate and coefficient of thermal expansion. In this work, hardystonite (HT; Ca2ZnSi2O7) and sphene (SP; CaTiSiO5) glass–ceramic coatings with nanostructures were prepared by a plasma spray technique using conventional powders. The bonding strength and Vickers hardness for HT and SP coatings are higher than the reported values for plasma-sprayed hydroxyapatite coatings. Both types of coatings release bioactive calcium (Ca) and silicon (Si) ions into the surrounding environment. Mineralization test in cell-free culture medium showed that many mushroom-like Ca and phosphorus compounds formed on the HT coatings after 5 h, suggesting its high acellular mineralization ability. Primary human osteoblasts attach, spread and proliferate well on both types of coatings. Higher proliferation rate was observed on the HT coatings compared with the SP coatings and uncoated Ti-6Al-4V alloy, probably due to the zinc ions released from the HT coatings. Higher expression levels of Runx2, osteopontin and type I collagen were observed on both types of coatings compared with Ti-6Al-4V alloy, possibly due to the Ca and Si released from the coatings. Results of this study point to the potential use of HT and SP coatings for orthopaedic applications. PMID:21292725

  4. Nanostructured glass-ceramic coatings for orthopaedic applications.

    PubMed

    Wang, Guocheng; Lu, Zufu; Liu, Xuanyong; Zhou, Xiaming; Ding, Chuanxian; Zreiqat, Hala

    2011-08-07

    Glass-ceramics have attracted much attention in the biomedical field, as they provide great possibilities to manipulate their properties by post-treatments, including strength, degradation rate and coefficient of thermal expansion. In this work, hardystonite (HT; Ca2ZnSi2O7) and sphene (SP; CaTiSiO5) glass-ceramic coatings with nanostructures were prepared by a plasma spray technique using conventional powders. The bonding strength and Vickers hardness for HT and SP coatings are higher than the reported values for plasma-sprayed hydroxyapatite coatings. Both types of coatings release bioactive calcium (Ca) and silicon (Si) ions into the surrounding environment. Mineralization test in cell-free culture medium showed that many mushroom-like Ca and phosphorus compounds formed on the HT coatings after 5 h, suggesting its high acellular mineralization ability. Primary human osteoblasts attach, spread and proliferate well on both types of coatings. Higher proliferation rate was observed on the HT coatings compared with the SP coatings and uncoated Ti-6Al-4V alloy, probably due to the zinc ions released from the HT coatings. Higher expression levels of Runx2, osteopontin and type I collagen were observed on both types of coatings compared with Ti-6Al-4V alloy, possibly due to the Ca and Si released from the coatings. Results of this study point to the potential use of HT and SP coatings for orthopaedic applications.

  5. Nanostructural Characteristics of Vacuum Cold-Sprayed Hydroxyapatite/Graphene-Nanosheet Coatings for Biomedical Applications

    NASA Astrophysics Data System (ADS)

    Liu, Yi; Huang, Jing; Li, Hua

    2014-10-01

    Development of novel biocompatible nanomaterials has provided insights into their potential biomedical applications. Bulk fabrication of the nanomaterials in the form of coatings remains challenging. Here, we report hydroxyapatite (HA)/graphene-nanosheet (GN) composite coatings deposited by vacuum cold spray (VCS). Significant shape changes of HA nanograins during the coating deposition were revealed. The nanostructural features of HA together with curvature alternation of GN gave rise to dense structures. Based on the microstructural characterization, a structure model was proposed to elucidate the nanostructural characteristics of the HA-GN nanocomposites. Results also showed that addition of GN significantly enhanced fracture toughness and elastic modulus of the HA-based coatings, which is presumably accounted for by crack bridging offered by GN in the composites. The VCS HA-GN coatings show potential for biomedical applications for the repair or replacement of hard tissues.

  6. Phase transitions of hydroxyapatite coatings during post-heat treatment and their performances under ultrasonic tests.

    PubMed

    Tong, W; Li, X; Feng, J; Chen, J; Zhang, X

    2001-07-01

    Highly or completely crystalline hydroxyapatite (HA) coatings can be obtained by post-heat treatment. We have developed a high-temperature (490 degrees C) and a low-temperature (125 degrees C) heat treatment to improve the crystallinity of HA coatings. Both methods transform entirely the amorphous phase into crystalline HA. However, the microstructure of the coating is dependent on the post-heating method. Nanocrystalline HA is about half of the component of the low-temperature heated coating while highly crystalline HA dominates the high-temperature heated coating, as detected by X-ray diffraction. The effects of both methods on the disintegration of the coatings were tested by ultrasonic treatment. The high-temperature heated coatings exhibited poor integrity while the low-temperature heated coatings exhibited better integrity, possibly due to their different microstructure. SEM revealed that the coatings disintegrated via different mechanisms: the high-temperature heated coatings failed via crack initiation and propagation while the low-temperature heated coatings failed via pit formation and subsequent widening.

  7. Bioactive composite gradient coatings of nano-hydroxyapatite/polyamide66 fabricated on polyamide66 substrates

    PubMed Central

    Huang, Di; Zuo, Yi; Li, Jidong; Zou, Qin; Zhang, Li; Gong, Mei; Wang, Li; Li, Limei; Li, Yubao

    2012-01-01

    Tightly bonding of bioactive coating is the first crucial need for orthopaedic implants. This study describes a novel and convenient technique to prepare bioactive coating with high adhesion on orthopaedic substitutes made of polymeric matrix. Here, a chemical corrosion method has been adopted to fabricate a coating on the surface of injection-moulded polyamide66 (PA66) substrates by corrosive nano-hydroxyapatite/polyamide66 (n-HA/PA66) composite slurry. Scanning electron microscopy observation shows that a porous chemical corrosion region presents between the coating and dense PA66 substrate. Energy-dispersive X-ray spectroscopy analysis indicates that the chemical corrosion region is mainly composed of PA66 matrix, and the coating layer is an n-HA-rich layer. Both the pore size and n-HA composition increase gradually from the polymeric substrate towards the coating surface. Mechanical testing shows the bonding strength can reach 13.7 ± 0.2 MPa, which is much higher than that fabricated on polymeric matrix by other coating methods. The gradual transition in coating structure and composition benefits for the interface bonding and for the surface bone-bonding bioactivity. Subsequent cell experiments corroborate n-HA-rich coating and a porous structure is benefitting for cell attachment and proliferation. The convenient coating method could be popularized and applied on similar polymer implants to produce a tightly and porous bioactive coating for bone tissue regeneration. PMID:22258549

  8. Synthesis of chitosan/hydroxyapatite membranes coated with hydroxycarbonate apatite for guided tissue regeneration purposes

    NASA Astrophysics Data System (ADS)

    Fraga, Alexandre Félix; Filho, Edson de Almeida; Rigo, Eliana Cristina da Silva; Boschi, Anselmo Ortega

    2011-02-01

    Chitosan, which is a non-toxic, biodegradable and biocompatible biopolymer, has been widely researched for several applications in the field of biomaterials. Calcium phosphate ceramics stand out among the so-called bioceramics for their absence of local or systemic toxicity, their non-response to foreign bodies or inflammations, and their apparent ability to bond to the host tissue. Hydroxyapatite (HA) is one of the most important bioceramics because it is the main component of the mineral phase of bone. The aim of this work was to produce chitosan membranes coated with hydroxyapatite using the modified biomimetic method. Membranes were synthesized from a solution containing 2% of chitosan in acetic acid (weight/volume) via the solvent evaporation method. Specimens were immersed in a sodium silicate solution and then in a 1.5 SBF (simulated body fluid) solution. The crystallinity of the HA formed over the membranes was correlated to the use of the nucleation agent (the sodium silicate solution itself). Coated membranes were characterized by means of scanning electron microscopy - SEM, X-ray diffraction - XRD, and Fourier transform infrared spectroscopy - FTIR. The results indicate a homogeneous coating covering the entire surface of the membrane and the production of a semi-crystalline hydroxyapatite layer similar to the mineral phase of human bone.

  9. Effect of Nano-Si3N4 Additives and Plasma Treatment on the Dry Sliding Wear Behavior of Plasma Sprayed Al2O3-8YSZ Ceramic Coatings

    NASA Astrophysics Data System (ADS)

    Gou, Junfeng; Zhang, Jian; Zhang, Qiwen; Wang, You; Wang, Chaohui

    2017-02-01

    In this paper, the effect of nano-Si3N4 additives and plasma treatment on the wear behavior of Al2O3-8YSZ ceramic coatings was studied. Nano-Al2O3, nano-8YSZ (8 wt.% Y2O3-stabilized ZrO2) and nano-Si3N4 powders were used as raw materials to fabricate four types of sprayable feedstocks. Plasma treatment was used to improve the properties of the feedstocks. The surface morphologies of the ceramic coatings were observed. The mechanical properties of the ceramic coatings were measured. The dry sliding wear behavior of the Al2O3-8YSZ coatings with and without Si3N4 additives was studied. Nano-Si3N4 additives and plasma treatment can improve the morphologies of the coatings by prohibiting the initiation of micro-cracks and reducing the unmelted particles. The hardness and bonding strength of AZSP (Al2O3-18 wt.% 8YSZ-10 wt.% Si3N4-plasma treatment) coating increased by 79.2 and 44% compared to those of AZ (Al2O3-20 wt.% 8YSZ) coating. The porosity of AZSP coating decreased by 85.4% compared to that of AZ coating. The wear test results showed that the addition of nano-Si3N4 and plasma treatment could improve the wear resistance of Al2O3-8YSZ coatings.

  10. Thermomechanical processing of plasma sprayed intermetallic sheets

    DOEpatents

    Hajaligol, Mohammad R.; Scorey, Clive; Sikka, Vinod K.; Deevi, Seetharama C.; Fleischhauer, Grier; Lilly, Jr., A. Clifton; German, Randall M.

    2001-01-01

    A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.0.05% Zr .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Ni, .ltoreq.0.75% C, .ltoreq.0.1% B, .ltoreq.1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, and/or .ltoreq.3% Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 .mu.m. Final stress relief annealing can be carried out in the B2 phase temperature range.

  11. Biodegradation rate of shellac coated bovine hydroxyapatite for bone filler material

    NASA Astrophysics Data System (ADS)

    Triyono, Joko; Triyono, Susilowati, Endang; Murdiyantara, Suci Anindya

    2016-03-01

    This work reports on the effect of shellac coated hydroxyapatite (HA) on the biodegradation rate. The HA was processed from bovine bone. Shellac was derived from the resinous secretion of the lac insect. The aims of the addition of shellac solution is to know how the biodegradation rate material in the Phosphate Buffered Saline (PBS) solution. The four different of shellac solutions (2,5%; 5%; 7,5%; and 10% weight) coated HA scaffoldand one ratio as a control. It was concluded that the ability of biodegradation rate a materialwas not influenced by the ratio of shellac. All materials were biodegradedwhen they were soaked in PBS solution.

  12. Corrosion behavior and biocompatibility of strontium and fluorine co-doped electrodeposited hydroxyapatite coatings

    NASA Astrophysics Data System (ADS)

    Huang, Yong; Ding, Qiongqiong; Pang, Xiaofeng; Han, Shuguang; Yan, Yajing

    2013-10-01

    To improve the corrosion resistance and biocompatibility of biomedical titanium, strontium (Sr) and fluorine (F) were simultaneously incorporated in hydroxyapatite (HAp) to form SrFHAp coating on titanium (Ti) via electrodeposition. The microstructure, phase composition, corrosion resistance, and cytocompatibility of the films were studied. Results revealed that by incorporating F- and Sr2+ ions in HAp, the density of the coating markedly increased, i.e., a lower porosity than common HAp coating. The SrFHAp layer was dense and uniform, with nano-needle-like crystals of apatite, which aligned vertically to the substrate. The SrFHAp crystals were calcium-deficient apatite, and Sr2+ ions and F- ions were homogeneously distributed in the coating. The SrFHAp coating showed lower dissolution rate than HA coating. Potentiodynamic polarization test manifested that the SrFHAp-coated titanium exhibited superior corrosion resistance than HAp single-coated sample. In addition, osteoblasts cellular tests revealed that the SrFHAp coating was more effective to improve the in vitro biocompatibility of Ti compared with HAp coating.

  13. MAO-derived hydroxyapatite/TiO2 nanostructured multi-layer coatings on titanium substrate

    NASA Astrophysics Data System (ADS)

    Abbasi, S.; Golestani-Fard, F.; Rezaie, H. R.; Mirhosseini, S. M. M.

    2012-11-01

    In this study, titanium substrates which previously oxidized through Micro arc oxidation method, was coated by Hydroxyapatite (HAp) coating once more by means of the same method. Morphology, topography and chemical properties as well as phase composition and thickness of layers were studied to reveal the effect of the electrolyte concentration on coating features. According to results, the obtained coatings are consisted of HAp and titania as the major phases along with minor amounts of calcium titanate and α-tri calcium phosphate. Ca and P are present on surface of obtained layers as well as predictable Ti and O based on the XPS results. Thickness profile of coatings figured out that by increasing the electrolyte concentration, especially by addition of more Calcium Acetate (CA) to electrolyte, the thickness of HAp layer would rise, consequently. However, the influence of coating time on thickness of obtained coatings would be more considerable than electrolyte concentration. High specific area coatings with nest morphology were obtained in Electrolyte containing 5 g/L β-Glycero Phosphate (β-GP) and 5 g/L CA. Increasing coating duration time in this kind of coatings would cause deduction of the nesting in their structure.

  14. Cellulose acetate/hydroxyapatite/chitosan coatings for improved corrosion resistance and bioactivity.

    PubMed

    Zhong, Zhenyu; Qin, Jinli; Ma, Jun

    2015-04-01

    Cellulose acetate (CA) nanofibers were deposited on stainless steel plates by electrospinning technique. The composite of hydroxyapatite (HAP) nanoparticles and chitosan (CHI) was coated subsequently by dip-coating. The structure and morphology of the obtained coatings were investigated by Fourier transform infrared spectroscopy and scanning electron microscopy. The stability of the coatings in physiological environment was studied using electrochemical polarization and impedance spectroscopy. The CA nanofibers were embedded in the HAP/CHI coating and the resulted composite film was densely packed and uniform on the substrate. The in vitro biomineralization study of the coated samples immersed in simulated body fluid (SBF) confirmed the formation ability of bone-like apatite layer on the surface of HAP-containing coatings. Furthermore, the coatings could provide corrosion resistance to the stainless steel substrate in SBF. The electrochemical results suggested that the incorporation of CA nanofibers could improve the corrosion resistance of the HAP/CHI coating. Thus, biocompatible CA/HAP/CHI coated metallic implants could be very useful in the long-term stability of the biomedical applications.

  15. In situ synthesis of hydroxyapatite coating by laser cladding.

    PubMed

    Wang, D G; Chen, C Z; Ma, J; Zhang, G

    2008-10-15

    HA bioceramic coatings were synthesized on titanium substrate by laser cladding using cheap calcium carbonate and calcium hydrogen phosphate. The thermodynamic condition for synthesizing HA was calculated by software Matlab 5.0, the microstructure and phase analysis of laser clad HA bioceramic coatings were studied by electron probe microanalyser (EPMA), X-ray diffractometer (XRD) and transmission electron microscopy (TEM). The theoretical results show that the Gibbs free enthalpy for the synthesis of HA phase is satisfied, and the presence of HA phase in the clad coatings was then further verified by XRD and the selected area diffraction patterns. When the laser power is 600W and the scanning speed is 3.5mm/s, the compact HA bioceramic coatings were obtained, which have cellular dendritic structure and consist of the phases of HA, alpha-Ca(2)P(2)O(7), CaO and CaTiO(3).

  16. Study on the neotype zirconia's implant coated nanometer hydroxyapatite ceramics

    NASA Astrophysics Data System (ADS)

    Zhu, J. W.; Yang, D. W.

    2007-07-01

    In recent years, biologic ceramics is a popular material of implants and bioactive surface modification of dental implant became a research emphasis, which aims to improve bioactivity of implants materials and acquire firmer implants-bone interface. The zirconia ceramic has excellent mechanical properties and nanometer HA ceramics is a bioceramic well known for its bioactivity, therefore, nanometer HA ceramics coating on zirconia, allows combining the excellent mechanical properties of zirconia substrates with its bioactivity. This paper shows a new method for implant shape design and bioactive modification of dental implants surface. Zirconia's implant substrate was prepared by sintered method, central and lateral tunnels were drilled in the zirconia hollow porous cylindrical implants by laser processing. The HA powders and needle-like HA crystals were made by a wet precipitation and calcining method. Its surface was coated with nanometer HA ceramics which was used brush HA slurry and vacuum sintering. Mechanical testing results revealed that the attachment strength of nanometer HA ceramics coated zirconia samples is high. SEM and interface observation after inserted experiment indicated that calcium and phosphor content increased and symmetrically around coated implant-bone tissue interface. A significantly higher affinity index was demonstrated in vivo by histomorphometric evaluation in coated versus uncoated implants. SEM analysis demonstrated better bone adhesion to the material in coated implant at any situation. In addition, the hollow porous cylindrical implant coated with nanometer HA ceramics increase the interaction of bone and implant, the new bone induced into the surface of hollow porous cylindrical implant and through the most tunnels filled into central hole. The branch-like structure makes the implant and bone a body, which increased the contact area and decreased elastic ratio. Therefore, the macroscopical and microcosmic nested structure of

  17. Plasma Spray Synthesis Of Nanostructured V2O5 Films For Electrical Energy Storage

    SciTech Connect

    Nanda, Jagjit

    2011-01-01

    We demonstrate for the first time, the synthesis of nanostructured vanadium pentoxide (V2O5) films and coatings using plasma spray technique. V2O5 has been used in several applications such as catalysts, super-capacitors and also as an electrode material in lithium ion batteries. In the present studies, V2O5 films were synthesized using liquid precursors (vanadium oxychloride and ammonium metavanadate) and powder suspension. In our approach, the precursors were atomized and injected radially into the plasma gun for deposition on the substrates. During the flight towards the substrate, the high temperature of the plasma plume pyrolyzes the precursor particles resulting into the desired film coatings. These coatings were then characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), Transmission electron microscopy (TEM) and Differential Scanning Calorimetry (DSC). Among the precursors, vanadium oxychloride gave the best results in terms of nanocrystalline and monophasic films. Spraying of commercial powder suspension yielded multi-phasic mixture in the films. Our approach enables deposition of large area coatings of high quality nanocrystalline films of V2O5 with controllable particle morphology. This has been optimized by means of control over precursor composition and plasma spray conditions. Initial electrochemical studies of V2O5 film electrodes show potential for energy storage studies.

  18. Modeling the Effect of Temperature and Potential on the In Vitro Corrosion Performance of Biomedical Hydroxyapatite Coatings

    NASA Astrophysics Data System (ADS)

    Coşkun, M. İbrahim; Karahan, İsmail H.; Yücel, Yasin; Golden, Teresa D.

    2016-10-01

    CoCrMo biomedical alloys were coated with a hydroxyapatite layer to improve biocompatibility and in vitro corrosion performance. A fast electrodeposition process was completed in 5 minutes for the hydroxyapatite coating. Effect of the solution temperature and applied potential on the in vitro corrosion performance of the hydroxyapatite coatings was modeled by response surface methodology (RSM) coupled with central composite design (CCD). A 5-level-2-factor experimental plan designed by CCD was used; the experimental plan contained 13 coating experiments with a temperature range from 283 K to 347 K (10 °C to 74 °C) and potential range from -1.2 to -1.9 V. Corrosion potential ( E corr) of the coatings in a simulated body fluid solution was chosen as response for the model. Predicted and experimental values fitted well with an R 2 value of 0.9481. Response surface plots of the impedance and polarization resistance ( R P) were investigated. Optimized parameters for electrodeposition of hydroxyapatite were determined by RSM as solution temperature of 305.48 K (32.33 °C) and potential of -1.55 V. Hydroxyapatite coatings fabricated at optimized parameters showed excellent crystal formation and high in vitro corrosion resistance.

  19. Electrophoretic deposition and electrochemical behavior of novel graphene oxide-hyaluronic acid-hydroxyapatite nanocomposite coatings

    NASA Astrophysics Data System (ADS)

    Li, Ming; Liu, Qian; Jia, Zhaojun; Xu, Xuchen; Shi, Yuying; Cheng, Yan; Zheng, Yufeng; Xi, Tingfei; Wei, Shicheng

    2013-11-01

    Novel ternary graphene oxide-hyaluronic acid-hydroxyapatite (GO-HY-HA) nanocomposite coatings were prepared on Ti substrate using anodic electrophoretic deposition (EPD). Hyaluronic acid was employed as charging additive and dispersion agent during EPD. The kinetics and mechanism of the deposition, and the microstructure of the coated samples were investigated using scanning electron microscopy, X-ray diffraction, Raman spectrum, thermo-gravimetric analysis, and microscopic Fourier transform infrared analysis. The results showed that the addition of GO sheets into the HY-HA suspensions could increase the deposition rate and inhibit cracks creation and propagation in the coatings. The corrosion resistant of the resulting samples were evaluated using potentiodynamic polarization method in simulated body fluid, and the GO-HY-HA coatings could effectively improve the anti-corrosion property of the Ti substrate.

  20. Antimicrobial peptide coatings for hydroxyapatite: electrostatic and covalent attachment of antimicrobial peptides to surfaces.

    PubMed

    Townsend, Leigh; Williams, Richard L; Anuforom, Olachi; Berwick, Matthew R; Halstead, Fenella; Hughes, Erik; Stamboulis, Artemis; Oppenheim, Beryl; Gough, Julie; Grover, Liam; Scott, Robert A H; Webber, Mark; Peacock, Anna F A; Belli, Antonio; Logan, Ann; de Cogan, Felicity

    2017-01-01

    The interface between implanted devices and their host tissue is complex and is often optimized for maximal integration and cell adhesion. However, this also gives a surface suitable for bacterial colonization. We have developed a novel method of modifying the surface at the material-tissue interface with an antimicrobial peptide (AMP) coating to allow cell attachment while inhibiting bacterial colonization. The technology reported here is a dual AMP coating. The dual coating consists of AMPs covalently bonded to the hydroxyapatite surface, followed by deposition of electrostatically bound AMPs. The dual approach gives an efficacious coating which is stable for over 12 months and can prevent colonization of the surface by both Gram-positive and Gram-negative bacteria.

  1. Hydroxyapatite coatings on nanotubular titanium dioxide thin films prepared by radio frequency magnetron sputtering.

    PubMed

    Shin, Jinho; Lee, Kwangmin; Koh, Jeongtae; Son, Hyeju; Kim, Hyunseung; Lim, Hyun-Pil; Yun, Kwidug; Oh, Gyejeong; Lee, Seokwoo; Oh, Heekyun; Lee, Kyungku; Hwang, Gabwoon; Park, Sang-Won

    2013-08-01

    In this study, hydroxyapatite (HA) was coated on anodized titanium (Ti) surfaces through radio frequency magnetron sputtering in order to improve biological response of the titanium surface. All the samples were blasted with resorbable blasting media (RBM). RBM-blasted Ti surface, anodized Ti surface, as-sputtered HA coating on the anodized Ti surface, and heat-treated HA coating on the anodized Ti surface were prepared. The samples were characterized using scanning electron microscopy and X-ray photoemission spectroscopy, and biologic responses were evaluated. The top of the TiO2 nanotubes was not closed by HA particles when the coating time is less than 15 minutes. It was demonstrated that the heat-treated HA was well-crystallized and this enhanced the cell attachment of the anodized Ti surface.

  2. Synthesis and characterization of bulk and coatings of hydroxyapatite using methanol precursor

    SciTech Connect

    Khongwar, Jasper K.; Kannan, K.R.; Buvaneswari, G.

    2008-02-05

    Hydroxyapatite, an important bioceramic was synthesized in the bulk form and developed as a coating by a sol-gel route using alcoholic precursor. The bioactive coating was developed on bio-inert {alpha}-alumina and yttria stabilized zirconia substrates. The apatite phase began to form after the heat treatment of the precursor at 500 deg. C for 10 min. The complete crystallization of the apatite was obtained at 800 deg. C heat treatment for 10 min. The phase composition of the bulk and the coatings was identified by FT-IR spectroscopic and powder X-ray diffraction (XRD) techniques. Surface morphology was determined by scanning electron microscopy. The study indicates different surface textures for the powder and for the coatings on {alpha}-alumina and yttria stabilized zirconia substrates.

  3. Ceramic coatings on smooth surfaces

    NASA Technical Reports Server (NTRS)

    Miller, R. A. (Inventor); Brindley, W. J. (Inventor); Rouge, C. J. (Inventor)

    1991-01-01

    A metallic coating is plasma sprayed onto a smooth surface of a metal alloy substitute or on a bond coating. An initial thin ceramic layer is low pressure sprayed onto the smooth surface of the substrate or bond coating. Another ceramic layer is atmospheric plasma sprayed onto the initial ceramic layer.

  4. Fabrication and characterization of modified-hydroxyapatite/polyetheretherketone coating materials

    NASA Astrophysics Data System (ADS)

    Ma, Rui; Fang, Lin; Luo, Zhongkuan; Zheng, Ruisheng; Song, Shenhua; Weng, Luqian; Lei, JinPing

    2014-09-01

    45 wt%-Hydroxyaptite/polyetheretherketone (HA/PEEK) coating materials modified by silane coupling agent (KH560) on PEEK substrate were successfully fabricated by solution casting method and characterized by Fourier transform infrared spectroscopy (FTIR), X-Ray Diffraction (XRD), scanning electron microscopy (SEM), and tensile testing. The modified HA fillers were obtained to be uniformly distributed in the HA/PEEK coating, which has better properties of tensile strength and fracture toughness than those of the unmodified specimen. A good bonding between the composite coating and the PEEK substrate was achieved by solution casting method, resulting in integral-fracture without falling apart or delaminating during tensile loading. The modified specimens dipped into simulated body fluid (SBF) were characterized by SEM, XRD and FTIR, indicating that the bioactivity of the dipped materials was demonstrated more apparent with extending the dipping time. Therefore, the coating materials may become the substitutes for the hard tissues of the human body in the future, which could realize the balance between the mechanical properties and the bioactivity by modifying the structural design of the coating.

  5. Preparation and Characterization of Lanthanum-Incorporated Hydroxyapatite Coatings on Titanium Substrates

    PubMed Central

    Lou, Weiwei; Dong, Yiwen; Zhang, Hualin; Jin, Yifan; Hu, Xiaohui; Ma, Jianfeng; Liu, Jinsong; Wu, Gang

    2015-01-01

    Titanium (Ti) has been widely used in clinical applications for its excellent biocompatibility and mechanical properties. However, the bioinertness of the surface of Ti has motivated researchers to improve the physicochemical and biological properties of the implants through various surface modifications, such as coatings. For this purpose, we prepared a novel bioactive material, a lanthanum-incorporated hydroxyapatite (La-HA) coating, using a dip-coating technique with a La-HA sol along with post-heat treatment. The XRD, FTIR and EDX results presented in this paper confirmed that lanthanum was successfully incorporated into the structure of HA. The La-HA coating was composed of rod-like particles which densely compacted together without microcracks. The results of the interfacial shear strength test indicated that the incorporation of lanthanum increased the bonding strength of the HA coating. The mass loss ratios under acidic conditions (pH = 5.5) suggested that the La-HA coatings have better acid resistance. The cytocompatibility of the La-HA coating was also revealed by the relative activity of alkaline phosphatase, cellular morphology and cell proliferation assay in vitro. The present study suggested that La-HA coated on Ti has promising potential for applications in the development of a new type of bioactive coating for metal implants. PMID:26404255

  6. Rapid coating of AZ31 magnesium alloy with calcium deficient hydroxyapatite using microwave energy.

    PubMed

    Ren, Yufu; Zhou, Huan; Nabiyouni, Maryam; Bhaduri, Sarit B

    2015-04-01

    Due to their unique biodegradability, magnesium alloys have been recognized as suitable metallic implant materials for degradable bone implants and bioresorbable cardiovascular stents. However, the extremely high degradation rate of magnesium alloys in physiological environment has restricted its practical application. This paper reports the use of a novel microwave assisted coating technology to improve the in vitro corrosion resistance and biocompatibility of Mg alloy AZ31. Results indicate that a dense calcium deficient hydroxyapatite (CDHA) layer was uniformly coated on a AZ31 substrate in less than 10min. Weight loss measurement and SEM were used to evaluate corrosion behaviors in vitro of coated samples and of non-coated samples. It was seen that CDHA coatings remarkably reduced the mass loss of AZ31 alloy after 7days of immersion in SBF. In addition, the prompt precipitation of bone-like apatite layer on the sample surface during immersion demonstrated a good bioactivity of the CDHA coatings. Proliferation of osteoblast cells was promoted in 5days of incubation, which indicated that the CDHA coatings could improve the cytocompatibility of the AZ31 alloy. All the results suggest that the CDHA coatings, serving as a protective layer, can enhance the corrosion resistance and biological response of magnesium alloys. Furthermore, this microwave assisted coating technology could be a promising method for rapid surface modification of biomedical materials.

  7. Hydroxyapatite coatings with oriented nanoplate and nanorod arrays: Fabrication, morphology, cytocompatibility and osteogenic differentiation.

    PubMed

    Chen, Wei; Tian, Bo; Lei, Yong; Ke, Qin-Fei; Zhu, Zhen-An; Guo, Ya-Ping

    2016-10-01

    Hydroxyapatite (HA) crystals exhibit rod-like shape with c-axis orientation and plate-like shape with a(b)-axis orientation in vertebrate bones and tooth enamel surfaces, respectively. Herein, we report the synthesis of HA coatings with the oriented nanorod arrays (RHACs) and HA coatings with oriented nanoplate arrays (PHACs) by using bioglass coatings as sacrificial templates. After soaking in simulated body fluid (SBF) at 120°C, the bioglass coatings are hydrothermally converted into the HA coatings via a dissolution-precipitation reaction. If the Ca/P ratios in SBF are 2.50 and 1.25, the HA crystals on the coatings are oriented nanorod arrays and oriented nanoplate arrays, respectively. Moreover, the bioglass coatings are treated with SBF at 37°C, plate-like HA coatings with a low crystallinity (SHACs) are prepared. As compared with the Ti6Al4V and SHACs, the human bone marrow stromal cells (hBMSCs) on the RHACs and PHACs have better cell adhesion, spreading, proliferation and osteogenic differentiation because of their moderately hydrophilic surfaces and similar chemical composition, morphology and crystal orientation to human hard tissues. Notably, the morphologies of HA crystals have no obvious effects on cytocompatibility and osteogenic differentiation. Hence, the HA coatings with oriented nanoplate arrays or oriented nanorod arrays have a great potential for orthopedic applications.

  8. Nano-Ag-loaded hydroxyapatite coatings on titanium surfaces by electrochemical deposition.

    PubMed

    Lu, Xiong; Zhang, Bailin; Wang, Yingbo; Zhou, Xianli; Weng, Jie; Qu, Shuxin; Feng, Bo; Watari, Fumio; Ding, Yonghui; Leng, Yang

    2011-04-06

    Hydroxyapatite (HA) coatings on titanium (Ti) substrates have attracted much attention owing to the combination of good mechanical properties of Ti and superior biocompatibility of HA. Incorporating silver (Ag) into HA coatings is an effective method to impart the coatings with antibacterial properties. However, the uniform distribution of Ag is still a challenge and Ag particles in the coatings are easy to agglomerate, which in turn affects the applications of the coatings. In this study, we employed pulsed electrochemical deposition to co-deposit HA and Ag simultaneously, which realized the uniform distribution of Ag particles in the coatings. This method was based on the use of a well-designed electrolyte containing Ag ions, calcium ions and l-cysteine, in which cysteine acted as the coordination agent to stabilize Ag ions. The antibacterial and cell culture tests were used to evaluate the antibacterial properties and biocompatibility of HA/Ag composite coatings, respectively. The results indicated the as-prepared coatings had good antibacterial properties and biocompatibility. However, an appropriate silver content should be chosen to balance the biocompatibility and antibacterial properties. Heat treatments promoted the adhesive strength and enhanced the biocompatibility without sacrificing the antibacterial properties of the HA/Ag coatings. In summary, this study provided an alternative method to prepare bioactive surfaces with bactericidal ability for biomedical devices.

  9. PCL-coated hydroxyapatite scaffold derived from cuttlefish bone: morphology, mechanical properties and bioactivity.

    PubMed

    Milovac, Dajana; Gallego Ferrer, Gloria; Ivankovic, Marica; Ivankovic, Hrvoje

    2014-01-01

    In the present study, poly(ε-caprolactone)-coated hydroxyapatite scaffold derived from cuttlefish bone was prepared. Hydrothermal transformation of aragonitic cuttlefish bone into hydroxyapatite (HAp) was performed at 200°C retaining the cuttlebone architecture. The HAp scaffold was coated with a poly(ε-caprolactone) (PCL) using vacuum impregnation technique. The compositional and morphological properties of HAp and PCL-coated HAp scaffolds were studied by means of X-ray diffraction (XRD), Fourier transform infrared (FTIR) spectroscopy, thermogravimetric analysis (TGA) and scanning electron microscopy (SEM) with energy dispersive X-ray (EDX) analysis. Bioactivity was tested by immersion in Hank's balanced salt solution (HBSS) and mechanical tests were performed at compression. The results showed that PCL-coated HAp (HAp/PCL) scaffold resulted in a material with improved mechanical properties that keep the original interconnected porous structure indispensable for tissue growth and vascularization. The compressive strength (0.88MPa) and the elastic modulus (15.5MPa) are within the lower range of properties reported for human trabecular bones. The in vitro mineralization of calcium phosphate (CP) that produces the bone-like apatite was observed on both the pure HAp scaffold and the HAp/PCL composite scaffold. The prepared bioactive scaffold with enhanced mechanical properties is a good candidate for bone tissue engineering applications.

  10. Some adhesion/cohesion characteristics of plasma-sprayed ZrO2-Y2O3 under tensile loading

    NASA Technical Reports Server (NTRS)

    Mullen, Robert L.; Vlcek, Brian L.; Hendricks, Robert C.; Mcdonald, Glen

    1987-01-01

    A set of 12.7 mm diameter stainless steel tubes were coated with ceramic and expanded. The bond cast was 0.08 to 0.13 mm NiCrAlY with 0.38 mm of ZrO2-8Y2O3 ceramic. Upon pressurization, the tube substrate yielded and overstressed the coatings in tension. The coatings cracked (i.e., they failed) but did not come off the tube. These results demonstrate that tensile failure of plasma-sprayed coatings is not catastrophic as is compressive failure, which leads to spallation.

  11. Effect of aluminum phosphate additions on composition of three-component plasma-sprayed solid lubricant

    NASA Technical Reports Server (NTRS)

    Jacobson, T. P.; Young, S. G.

    1982-01-01

    Image analysis (IA) and electron microprobe X-ray analysis (EMXA) were used to characterize a plasma-sprayed, self-lubricating coating, NASA LUBE PS106, specified by weight percent as 35NiCr-35Ag-30CaF2. To minimize segregation of the powder mixture during the plasma-spraying procedure, monoaluminum phosphate was added to form agglomerate particles. Three concentrations of AlPO4 were added to the mixtures: 1.25, 2.5, and 6.25 percent by weight. Analysis showed that 1.25 wt% AlPO4 yielded a CaF2 deficiency, 2.5 wt% kept the coating closest to specification, and 6.25 wt% yielded excess CaF2 as well as more impurities and voids and a deficiency in silver. Photomicrographs and X-ray maps are presented. The methods of IA and EMXA complement each other, and the reasonable agreement in the results increases the confidence in determining the coating composition.

  12. Effects of zinc-substituted nano-hydroxyapatite coatings on bone integration with implant surfaces*

    PubMed Central

    Zhao, Shi-fang; Dong, Wen-jing; Jiang, Qiao-hong; He, Fu-ming; Wang, Xiao-xiang; Yang, Guo-li

    2013-01-01

    Objective: The purpose of this study was to investigate the effects of a zinc-substituted nano-hydroxyapatite (Zn-HA) coating, applied by an electrochemical process, on implant osseointegraton in a rabbit model. Methods: A Zn-HA coating or an HA coating was deposited using an electrochemical process. Surface morphology was examined using field-emission scanning electron microscopy. The crystal structure and chemical composition of the coatings were examined using an X-ray diffractometer (XRD) and Fourier transform infrared spectroscopy (FTIR). A total of 78 implants were inserted into femurs and tibias of rabbits. After two, four, and eight weeks, femurs and tibias were retrieved and prepared for histomorphometric evaluation and removal torque (RTQ) tests. Results: Rod-like HA crystals appeared on both implant surfaces. The dimensions of the Zn-HA crystals seemed to be smaller than those of HA. XRD patterns showed that the peaks of both coatings matched well with standard HA patterns. FTIR spectra showed that both coatings consisted of HA crystals. The Zn-HA coating significantly improved the bone area within all threads after four and eight weeks (P<0.05), the bone to implant contact (BIC) at four weeks (P<0.05), and RTQ values after four and eight weeks (P<0.05). Conclusions: The study showed that an electrochemically deposited Zn-HA coating has potential for improving bone integration with an implant surface. PMID:23733429

  13. Sol-Gel-Derived Hydroxyapatite-Carbon Nanotube/Titania Coatings on Titanium Substrates

    PubMed Central

    Ji, Xiaoli; Lou, Weiwei; Wang, Qi; Ma, Jianfeng; Xu, Haihong; Bai, Qing; Liu, Chuantong; Liu, Jinsong

    2012-01-01

    In this paper, hydroxyapatite-carbon nanotube/titania (HA-CNT/TiO2) double layer coatings were successfully developed on titanium (Ti) substrates intended for biomedical applications. A TiO2 coating was firstly developed by anodization to improve bonding between HA and Ti, and then the layer of HA and CNTs was coated on the surface by the sol-gel process to improve the biocompatibility and mechanical properties of Ti. The surfaces of double layer coatings were uniform and crack-free with a thickness of about 7 μm. The bonding strength of the HA-CNT/TiO2 coating was higher than that of the pure HA and HA-CNT coatings. Additionally, in vitro cell experiments showed that CNTs promoted the adhesion of preosteoblasts on the HA-CNT/TiO2 double layer coatings. These unique surfaces combined with the osteoconductive properties of HA exhibited the excellent mechanical properties of CNTs. Therefore, the developed HA-CNT/TiO2 coatings on Ti substrates might be a promising material for bone replacement. PMID:22606041

  14. Silver/hydroxyapatite composite coatings on porous titanium surfaces by sol-gel method.

    PubMed

    Qu, Jie; Lu, Xiong; Li, Dan; Ding, Yonghui; Leng, Yang; Weng, Jie; Qu, Shuxin; Feng, Bo; Watari, Fumio

    2011-04-01

    Hydroxyapatite (HA) coatings loaded with nanosilver particles is an attractive method to impart the HA coating with antibacterial properties. Producing Ag/HA coatings on porous Ti substrates have been an arduous job since commonly used line-of-sight techniques are not able to deposit uniform coatings on the inner pore surfaces of the porous Ti. In this study, porous Ti scaffolds with high porosity and interconnected structures were prepared by polymer impregnating method. A sol-gel process was used to produce uniform Ag/HA composite coatings on the surfaces of porous Ti substrates. Ca(NO(3) )(2) ·4H(2) O and P(2) O(5) in an ethyl alcohol based system was selected to prepare the sol, which ensured the homogeneous distribution of Ag in the sol. The characterization revealed that silver particles uniformly distributed in the coatings without agglomeration. High antibacterial ratio (>95%), against E. coli and S. albus was expressed by the silver-containing coatings (Ag/HA 0.8 and 1.6 wt %). The biocompatibility of the Ag/HA 0.8 surfaces was as good as that of pure HA surface, as revealed by culturing osteoblasts on them. The results indicated that Ag/HA 0.8 had the good balance between the biocompatibility and antibacterial properties of the coatings.

  15. Sol-gel-derived hydroxyapatite-carbon nanotube/titania coatings on titanium substrates.

    PubMed

    Ji, Xiaoli; Lou, Weiwei; Wang, Qi; Ma, Jianfeng; Xu, Haihong; Bai, Qing; Liu, Chuantong; Liu, Jinsong

    2012-01-01

    In this paper, hydroxyapatite-carbon nanotube/titania (HA-CNT/TiO(2)) double layer coatings were successfully developed on titanium (Ti) substrates intended for biomedical applications. A TiO(2) coating was firstly developed by anodization to improve bonding between HA and Ti, and then the layer of HA and CNTs was coated on the surface by the sol-gel process to improve the biocompatibility and mechanical properties of Ti. The surfaces of double layer coatings were uniform and crack-free with a thickness of about 7 μm. The bonding strength of the HA-CNT/TiO(2) coating was higher than that of the pure HA and HA-CNT coatings. Additionally, in vitro cell experiments showed that CNTs promoted the adhesion of preosteoblasts on the HA-CNT/TiO(2) double layer coatings. These unique surfaces combined with the osteoconductive properties of HA exhibited the excellent mechanical properties of CNTs. Therefore, the developed HA-CNT/TiO(2) coatings on Ti substrates might be a promising material for bone replacement.

  16. Metallurgy and properties of plasma spray formed materials

    NASA Technical Reports Server (NTRS)

    Mckechnie, T. N.; Liaw, Y. K.; Zimmerman, F. R.; Poorman, R. M.

    1992-01-01

    Understanding the fundamental metallurgy of vacuum plasma spray formed materials is the key to enhancing and developing full material properties. Investigations have shown that the microstructure of plasma sprayed materials must evolve from a powder splat morphology to a recrystallized grain structure to assure high strength and ductility. A fully, or near fully, dense material that exhibits a powder splat morphology will perform as a brittle material compared to a recrystallized grain structure for the same amount of porosity. Metallurgy and material properties of nickel, iron, and copper base alloys will be presented and correlated to microstructure.

  17. A biodegradable gentamicin-hydroxyapatite-coating for infection prophylaxis in cementless hip prostheses.

    PubMed

    Neut, D; Dijkstra, R J; Thompson, J I; Kavanagh, C; van der Mei, H C; Busscher, H J

    2015-01-02

    A degradable, poly (lactic-co-glycolic acid) (PLGA), gentamicin-loaded prophylactic coating for hydroxyapatite (HA)-coated cementless hip prostheses is developed with similar antibacterial efficacy as offered by gentamicin-loaded cements for fixing traditional, cemented prostheses in bone. We describe the development pathway, from in vitro investigation of antibiotic release and antibacterial properties of this PLGA-gentamicin-HA-coating in different in vitro models to an evaluation of its efficacy in preventing implant-related infection in rabbits. Bone in-growth in the absence and presence of the coating was investigated in a canine model. The PLGA-gentamicin-HA-coating showed high-burst release, with antibacterial efficacy in agar-assays completely disappearing after 4 days, minimising risk of inducing antibiotic resistance. Gentamicin-sensitive and gentamicin-resistant staphylococci were killed by the antibiotic-loaded coating, in a simulated prosthesis-related interfacial gap. PLGA-gentamicin-HA-coatings prevented growth of bioluminescent staphylococci around a miniature-stem mounted in bacterially contaminated agar, as observed using bio-optical imaging. PLGA-gentamicin-HA-coated pins inserted in bacterially contaminated medullary canals in rabbits caused a statistically significant reduction in infection rates compared to HA-coated pins without gentamicin. Bone ingrowth to PLGA-gentamicin-HA-coated pins, in condylar defects of Beagle dogs was not impaired by the presence of the degradable, gentamicin-loaded coating. In conclusion, the PLGA-gentamicin-HA-coating constitutes an effective strategy for infection prophylaxis in cementless prostheses.

  18. Characterizing Sintered Nano-Hydroxyapatite Sol-Gel Coating Deposited on a Biomedical Ti-Zr-Nb Alloy

    NASA Astrophysics Data System (ADS)

    Jafari, Hassan; Hessam, Hamid; Shahri, Seyed Morteza Ghaffari; Assadian, Mahtab; Shairazifard, Shahin Hamtaie Pour; Idris, Mohd Hasbullah

    2016-03-01

    In this study, sol-gel dip-coating method was used to coat nano-hydroxyapatite on specimens of Ti-14Zr-13Nb alloy for orthopedic applications. The coated specimens were sintered at three different temperatures and time spans to evaluate the impact of sintering process on microstructure, mechanical, bio-corrosion, and bioactivity properties of the coating. Field-emission scanning electron microscopy and x-ray diffraction were used to analyze the coating microstructure. Coating adhesion and mechanical performance were also investigated by scratch testing. Besides, electrochemical corrosion and immersion tests were performed in simulated body fluid to examine the sintering effect on corrosion performance and bioactivity of the coatings, respectively. The evaluations of coated specimens displayed that sintering at elevated temperatures leads to higher surface integrity and improves crystallinity of the nano-hydroxyapatite to approximately 89% which brings about distinctively enhanced mechanical properties. Similarly, it improved the corrosion rate for about 17 times through sintering at 700 °C. Immersion test proved that the coating increased the bioactivity resulted from the dissolution of calcium phosphates into the corresponding environment. It is noticeable that sintering the dip-coated specimens in the nano-hydroxyapatite improves corrosion performance and maintains bioactive behaviors as well.

  19. Preparation and Characterization of Hydroxyapatite Coating on AZ31 Mg Alloy for Implant Applications

    PubMed Central

    Salman, S. A.; Kuroda, K.; Okido, M.

    2013-01-01

    Magnesium alloys as biodegradable metal implants in orthopaedic research received a lot of interest in recent years. They have attractive biological properties including being essential to human metabolism, biocompatibility, and biodegradability. However, magnesium can corrode too rapidly in the high-chloride environment of the physiological system, loosing mechanical integrity before the tissue has sufficiently healed. Hydroxyapatite (HAp) coating was proposed to decrease the corrosion rate and improve the bioactivity of magnesium alloy. Apatite has been cathodically deposited on the surface of Mg alloy from solution that composed of 3 mM Ca(H2PO4)2 and 7 mM CaCl2 at various applied potentials. The growing of HAp was confirmed on the surface of the coatings after immersion in SBF solution for 7 days. The coating obtained at −1.4 V showed higher corrosion resistance with bioactive behaviors. PMID:23533371

  20. Preparation and characterization of chitosan-silver/hydroxyapatite composite coatings onTiO2 nanotube for biomedical applications

    NASA Astrophysics Data System (ADS)

    Yan, Yajing; Zhang, Xuejiao; Li, Caixia; Huang, Yong; Ding, Qiongqiong; Pang, Xiaofeng

    2015-03-01

    A biocomposite coating containing chitosan, silver, and hydroxyapatite was developed on anodized titanium substrate by electrochemical deposition. Coatings were characterized by field-emission scanning electron microscopy, X-ray diffraction, Fourier transform infrared spectroscopy, X-ray photoelectron spectroscopy and polarisation studies. Results showed that the prepared coatings had compact and dense morphology with a thickness of 6.2 ± 0.7 μm and that silver was evenly distributed. Testing the prepared coatings with Gram-positive and Gram-negative bacterial strains exhibited antibacterial activity because of the synergistic effect of silver and chitosan. The prepared coatings were also found to be nontoxic to MC3T3-E1 cells. These results suggested that chitosan/silver-hydroxyapatite biocomposite coatings can prevent the bacterial infection of implants.

  1. Hydroxyapatite coating on PEEK implants: Biomechanical and histological study in a rabbit model.

    PubMed

    Durham, John W; Montelongo, Sergio A; Ong, Joo L; Guda, Teja; Allen, Matthew J; Rabiei, Afsaneh

    2016-11-01

    A bioactive two-layer coating consisting of hydroxyapatite (HA) and yttria-stabilized zirconia (YSZ) was investigated on cylindrical polyetheretherketone (PEEK) implants using ion beam assisted deposition (IBAD). Post-deposition heat treatments via variable frequency microwave annealing with and without subsequent autoclaving were used to crystallize the as-deposited amorphous HA layer. Microstructural analysis, performed by TEM and EDS, showed that these methods were capable of crystallizing HA coating on PEEK. The in vivo response to cylindrical PEEK samples with and without coating was studied by implanting uncoated PEEK and coated PEEK implants in the lateral femoral condyle of 18 rabbits. Animals were studied in two groups of 9 for observation at 6 or 18weeks post surgery. Micro-CT analysis, histology, and mechanical pull-out tests were performed to determine the effect of the coating on osseointegration. The heat-treated HA/YSZ coatings showed improved implant fixation as well as higher bone regeneration and bone-implant contact area compared to uncoated PEEK. The study offers a novel method to coat PEEK implants with improved osseointegration.

  2. Surface modification of pure titanium by hydroxyapatite-containing composite coatings

    NASA Astrophysics Data System (ADS)

    Zhao, Quan-Ming; Cheng, Li; Yang, Hui-Lin; Liu, Zhong-Tang; Feng, De-Hong

    2014-12-01

    Micro-arc oxidation (MAO) is commonly applied to modify the surface of titanium (Ti)-based medical implants with a bioactive and porous Ti oxide (TiO2) coating. The study reports a new method of incorporating hydroxyapatite (HA) within the TiO2 coating by MAO and alkali heat treatment (AHT) in the solution containing Ca ion and P ion. The morphology, composition and phase composition of the coatings were analyzed with scanning electron microscopy with energy-dispersive X-ray spectrometer and X-ray diffraction. Surface topography and roughness of the coatings were investigated by atomic force microscopy operated in the tapping mode. The results showed that TiO2-based coatings were obtained on pure Ti by MAO with an electrolyte containing Ca ion and P ion; the prepared MAO coatings were mainly composed of Ca, P, O and Ti. AHT transformed Ca and P to HA crystals. In conclusion, the TiO2/HA composite coatings can be obtained on the surface of pure Ti by MAO and AHT, and the addition of Ca ion and P ion to the AHT solution contributed to the formation of HA.

  3. Effect of the deposition temperature on corrosion resistance and biocompatibility of the hydroxyapatite coatings

    NASA Astrophysics Data System (ADS)

    Vladescu, A.; Braic, M.; Azem, F. Ak; Titorencu, I.; Braic, V.; Pruna, V.; Kiss, A.; Parau, A. C.; Birlik, I.

    2015-11-01

    Hydroxyapatite (HAP) ceramics belong to a class of calcium phosphate-based materials, which have been widely used as coatings on titanium medical implants in order to improve bone fixation and thus to increase the lifetime of the implant. In this study, HAP coatings were deposited from pure HAP targets on Ti6Al4V substrates using the radio-frequency magnetron sputtering technique at substrate temperatures ranging from 400 to 800 °C. The surface morphology and the crystallographic structure of the films were investigated by atomic force microscopy (AFM), scanning electron microscopy (SEM) and X-ray diffraction (XRD). The corrosion resistance of the coatings in saliva solution at 37 °C was evaluated by potentiodynamic polarization. Additionally, the human osteosarcoma cell line (MG-63) was used to test the biocompatibility of the coatings. The results showed that all of the coatings grown uniformly and that the increasing substrate temperature induced an increase in their crystallinity. Corrosion performance of the coatings was improved with the increase of the substrate temperature from 400 °C to 800 °C. Furthermore, all the coatings support the attachment and growth of the osteosarcoma cells with regard to the in vitro test findings.

  4. Bioactive glass coatings with hydroxyapatite and Bioglass (registered) particles on Ti-based implants. 1. Processing

    SciTech Connect

    Gomez-Vega, J.M.; Saiz, E.; Tomsia, A.P.; Marshall, G.W.; Marshall, S.J.

    1999-06-01

    Silicate-based glasses with thermal expansion coefficients that match those of Ti6Al4V were prepared and used to coat Ti6Al4V by a simple enameling technique. Bioglass (BG) (registered) or hydroxyapatite (HA) particles were embedded on the coatings in order to enhance their bioactivity. HA particles were partially embedded during heating and remained firmly embedded on the coating after cooling. There was no apparent reaction at the glass/HA interface at the temperatures used in this work (800-840 degrees C). In contrast, BG particles softened and some infiltration into the glass coating took place during heat treatment. In this case, particles with sizes over 45 (mu)m were required, otherwise the particles became hollow due to the infiltration and crystallization of the glass surface. The concentration of the particles on the coating was limited to 20% of surface coverage. Concentrations above this value resulted in cracked coatings due to excessive induced stress. Cracks did not prop agate along the interfaces when coatings were subjected to Vickers indentation tests, indicating that the particle/glass and glass/metal interfaces exhibited strong bonds. Enameling, producing excellent glass/metal adhesion with well-attached bioactive particles on the surface, is a promising method of forming reliable and lasting implants which can endure substantial chemical and mechanical stresses.

  5. Bioceramic coating of hydroxyapatite fabricated on Ti-6Al-4V with Nd-YAG laser

    NASA Astrophysics Data System (ADS)

    Tlotleng, Monnamme; Akinlabi, Esther T.; Shukla, Mukul; Pityana, Sisa

    2015-03-01

    This paper presents on the direct laser melted hydroxyapatite coatings achieved by melting the pre-placed powder beds using Nd-YAG laser. The process development and optimized parameters are reported. The results show that by changing the laser power and the beam inclined plane it is possible that a desirable coating of HAP that is rich on the surface can be produced. The microstructures of the coatings showed balling and cracking at beam angles between 0-15° and at 27° a successful coating was achieved with laser power and scanning speed of 750W and 5mm/s respectively. The said coating was pore and crack free while it retained non-decomposed HAP crystallites on the surface (mixed). The microstructure of the transition layer concluded a moderate temperature process since the formed dendrites did not develop or form secondary arms. The Ca/P conducted on the coating using EDS concluded Ca/P ratio of 8.04 and the absence of titanium phosphates phase (TiP2). TiP2 is typically associated with the decomposition of HAP and indicate the presence of high processing temperatures. Even so, the current results indicated that the investigated process was successful in depositing HAP coating with desirable microstructures even though its bio-corrosion properties still need to be ascertained before it could be qualified as suitable for biomedical applications.

  6. Randomized controlled clinical trial of 2 types of hydroxyapatite-coated implants on moderate periodontitis patients

    PubMed Central

    2016-01-01

    Purpose The aim of this study was to compare and analyze the peri-implant tissue conditions and prospective clinical outcomes associated with 2 types of hydroxyapatite (HA)-coated implants: (1) fully HA-coated implants and (2) partially HA-coated implants with resorbable blast medium on the coronal portion of the threads. Methods Forty-four partially edentulous patients were randomly assigned to undergo the placement of 62 HA-coated implants, and were classified as the control group (partially HA-coated, n=30) and the test group (fully HA-coated, n=32). All patients had chronic periodontitis with moderate crestal bone loss around the edentulous area. The stability and clinical outcomes of the implants were evaluated using the primary and secondary implant stability quotient (ISQ), as well as radiographic, mobility, and peri-implant soft tissue assessments around the implants. The Wilcoxon signed-rank test and the Mann-Whitney test were used to evaluate differences between and within the 2 groups, with P values <0.05 considered to indicate statistical significance. Results The fully HA-coated implants displayed good retention of crestal bone, and insignificant differences were found in annual marginal bone loss between the 2 types of HA-coated implants (P>0.05). No significant differences were found in the survival rate (group I, 100%; group II, 100%) or the success rate (group I, 93.3%; group II, 93.8%). The fully HA-coated implants also did not significantly increase the risk of peri-implantitis (P>0.05). Conclusions The fully HA-coated implants did not lead to an increased risk of peri-implantitis and showed good retention of the crestal bone, as well as good survival and success rates. Our study suggests that fully HA-coated implants could become a reliable treatment alternative for edentulous posterior sites and are capable of providing good retention of the crestal bone. PMID:27800216

  7. Hydroxyapatite porous scaffold engineered with biological polymer hybrid coating for antibiotic Vancomycin release.

    PubMed

    Kim, Hae-Won; Knowles, Jonathan C; Kim, Hyoun-Ee

    2005-03-01

    The purpose of this study is to improve hydroxyapatite (HA) porous scaffolds via coating with biological polymer-HA hybrids for use as wound healing and tissue regeneration. Highly porous HA scaffolds, fabricated by a polyurethane foam reticulate method, were coated with hybrid coating solution, consisting of poly(epsilon-caprolactone) (PCL), HA powders, and the antibiotic Vancomycin. The PCL to HA ratio was fixed at 1.5 and the drug amounts were varied [drug/(PCL + HA) = 0.02 and 0.04]. For the purpose of comparison, bare HA scaffold without the hybrid coating layer was also loaded with Vancomycin via an immersion-adsorption method. The hybrid coating structure and morphology were observed with Fourier transformed infrared (FT-IR) spectroscopy and scanning electron microscopy (SEM). The effects of the hybrid coating on the compressive mechanical properties and the in vitro drug release of the scaffolds were investigated in comparison with bare HA scaffold. The PCL-HA hybrid coating altered the scaffold pore structure slightly, resulting in thicker stems and reduced porosity. With the hybrid coating, the HA scaffold responded to an applied compressive stress more effectively without showing a brittle failure. This was attributed to the shielding and covering of the framework surface by the coating layer. The encapsulated drugs within the coated scaffold was released in a highly sustained manner as compared to the rapid release of drugs directly adsorbed on the pure HA scaffold. These findings suggest that the coated HA scaffolds expand their applicability in hard tissue regeneration and wound healing substitutes delivering bioactive molecules.

  8. Hydroxyapatite Coatings Produced by Surface-Induced Mineralizaiton

    SciTech Connect

    Campbell, Allison A.; Deatherage, Brooke L.; Li, Xiaohong S.; Nelson, Bradley J.; Bottoni, Craig R.; Dejong, E. Schuyler

    2002-01-03

    The surface-induced mineralization (SIM) process is based on the observation that, in nature, organisms use biopolymers to produce ceramic composites such as teeth, bones, and shells. The SIM process involves modification of a surface to introduce surface functionalization followed by immersion in aqueous supersaturated calcium phosphate solutions. This room temperature process has advantages over conventional methods of calcium phosphate deposition in that uniform coatings are produced onto complex-shaped and/or microporous samples. Additionally, because it is a room temperature process, biological agents can be incorporated.

  9. Hydroxyapatite nanocrystals functionalized with alendronate as bioactive components for bone implant coatings to decrease osteoclastic activity

    NASA Astrophysics Data System (ADS)

    Bosco, Ruggero; Iafisco, Michele; Tampieri, Anna; Jansen, John A.; Leeuwenburgh, Sander C. G.; van den Beucken, Jeroen J. J. P.

    2015-02-01

    The integration of bone implants within native bone tissue depends on periprosthetic bone quality, which is severely decreased in osteoporotic patients. In this work, we have synthesized bone-like hydroxyapatite nanocrystals (nHA) using an acid-base neutralization reaction and analysed their physicochemical properties. Subsequently, we have functionalized the nHA with alendronate (nHAALE), a well-known bisphosphonate drug used for the treatment of osteoporosis. An in vitro osteoclastogenesis test was carried out to evaluate the effect of nHAALE on the formation of osteoclast-like cells from monocytic precursor cells (i.e. RAW264.7 cell line) showing that nHAALE significantly promoted apoptosis of osteoclast-like cells. Subsequently, nHA and nHAALE were deposited on titanium disks using electrospray deposition (ESD), for which characterisation of the deposited coatings confirmed the presence of alendronate in nHAALE coatings with nanoscale thickness of about 700 nm. These results indicate that alendronate linked to hydroxyapatite nanocrystals has therapeutic potential and nHAALE can be considered as an appealing coating constituent material for orthopaedic and oral implants for application in osteoporotic patients.

  10. Performance of air plasma spraying parameters in the fabrication of ZrO2-10%Y2O3-18% TiO2 thermal barrier coatings

    NASA Astrophysics Data System (ADS)

    Liscano, S.; Gil, L.

    2013-11-01

    In this research, ZrO2-10%Y2O3-18% TiO2 thermal barrier coatings (TBCs) were sprayed by employing an air plasma thermal spray (APS) technique following a 23 factorial design experiment in order to obtain the best favorable spraying conditions able to enhance their properties. The effect of the spraying parameters on the porosity, microhardness, microstructure and morphology were determined by using different techniques such as optical microscopy (OP), image analysis, Vickers indentation and scanning electron microscopy (SEM) technique, this latter coupled with X-Ray microanalysis (EDS). It was found that both the arc voltage and the powder feed rate, as well as their interaction had a significant effect on the values of the reported hardness and these results were related to the existing level of porosity in the coatings. It was concluded that the best coatings properties, for the level of the variables studied in this work, could be obtained if the arc voltage is maintained at 36 V, the arc current at 900 A and the powder feed rate to 24 g/min.

  11. Characteristics of a Plasma Torch Designed for Very Low Pressure Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Gao, Yang; Yang, De Ming; Gao, Jianyi

    2012-06-01

    Unlike atmosphere plasma spraying (APS), very low pressure plasma spraying (VLPPS) can only weakly heat the feed materials at the plasma-free region exit of the nozzle. Most current VLPPS methods have adopted a high power plasma gun, which operates at high arc currents up to 2500 A to remedy the lower heating ability, causing a series of problems for both the plasma torch and the associated facility. According to the Kundsen number and pressures distribution inside of the nozzle in a low-pressure environment, a plasma torch was designed with a separated anode and nozzle, and with the powder feed to the plasma jets inside the nozzle intake. In this study, the pressures in the plasma gas intake, in the nozzle intake and outside the plasma torch were measured using an enthalpy probe. For practice, SUS 316 stainless steel coatings were prepared at the plasma currents of 500-600 A, an arc voltage of 50 V and a chamber pressure of 1000 Pa; the results indicated that coatings with an equiaxed microstructure could be deposited in proper conditions.

  12. Temperature Measurement Challenges and Limitations for In-Flight Particles in Suspension Plasma Spraying

    NASA Astrophysics Data System (ADS)

    Aziz, Bishoy; Gougeon, Patrick; Moreau, Christian

    2017-03-01

    Suspension plasma spraying (SPS) acquires a significant interest from the industry. The deposited coatings using this technique were proved to have unique microstructural features compared to those built by conventional plasma spraying techniques. In order to optimize this process, in-flight particle diagnostics is considered a very useful tool that helps to control various spraying parameters and permits better coating reproducibility. In that context, the temperature of in-flight particles is one of the most important key elements that helps to optimize and control the SPS process. However, the limitations and challenges associated with this process have a significant effect on the accuracy of two-color pyrometric techniques used to measure the in-flight particle temperature. In this work, the influence of several nonthermal radiation sources on the particle temperature measurement is studied. The plasma radiation scattered by in-flight particles was found to have no significant influence on temperature measurement. Moreover, the detection of the two-color signals at two different locations was found to induce a significant error on temperature measurement. Finally, the plasma radiation surrounding the in-flight particles was identified as the main source of error on the temperature measurement of in-flight particles.

  13. Effect of Powder Injection on the Interfacial Fracture Toughness of Plasma-Sprayed Zirconia

    NASA Astrophysics Data System (ADS)

    Okajima, Yoshifumi; Nakamura, Toshio; Sampath, Sanjay

    2013-03-01

    Adhesive strength of the plasma-sprayed thermal barrier coating is one of the most important parameters which influence their durability and reliability during service. While many methods exist to measure the adhesive strength, in general, they require cumbersome and time-consuming specimen preparation. Furthermore, considerations of the adhesion strength from the point-of-view of fracture toughness or for that matter, their systematic correlation to both processing variances are limited. Consequently, there is an opportunity to both simplify the measurement procedure and establish correlations among methods and linkages between processing parameters and interfacial fracture toughness. In this paper, we report results on adhesion strength of plasma-sprayed yttria-stabilized zirconia (YSZ) coating on aluminum substrates based on both interfacial indentation test (to measure interfacial fracture toughness) and the modified tensile adhesive test. Carrier gas flow for powder injection into the plasma torch was systematically varied to introduce variances in particle melting with concomitant impact on the measured adhesive strength. The results indicate the correlation between the particle melting index and the measured interfacial fracture toughness.

  14. Preventing Clogging In A Vacuum Plasma Spray Gun

    NASA Technical Reports Server (NTRS)

    Krotz, Phillip D.; Daniel, Ronald L., Jr.; Davis, William M.

    1994-01-01

    Modification of powder-injection ports enables lengthy, high-temperature deposition operations. Graphite inserts prevent clogging of ports through which copper powder injected into vacuum plasma spray (VPS) gun. Graphite liners eliminate need to spend production time refurbishing VPS gun, reducing cost of production and increasing productivity. Concept also applied to other material systems used for net-shape fabrication via VPS.

  15. Alignment Fixtures For Vacuum-Plasma-Spray Gun

    NASA Technical Reports Server (NTRS)

    Woodford, William H.; Mckechnie, Timothy N.; Power, Christopher A.; Daniel, Ronald L., Jr.

    1993-01-01

    Fixtures for alignment of vacuum-plasma-spray guns built. Each fixture designed to fit specific gun and holds small, battery-powered laser on centerline of gun. Laser beam projects small red dot where centerline intersects surface of workpiece to be sprayed. After laser beam positioned on surface of workpiece, fixture removed from gun and spraying proceeds.

  16. Removable Mandrels For Vacuum-Plasma-Spray Forming

    NASA Technical Reports Server (NTRS)

    Krotz, Phillip D.; Davis, William M.; Power, Christopher A.; Woodford, William H.; Todd, Douglas M.; Liaw, Yoon K.; Holmes, Richard R.; Zimmerman, Frank R.; Mckechnie, Timothy N.

    1995-01-01

    Improved mandrels developed for use in vacuum-plasma-spray (VPS) forming of refractory metal and ceramic furnace cartridge tubes. Designed so after tubes formed on them by VPS, mandrels shrink away from tubes upon cooling back to room temperature and simply slip out of tube.

  17. Porous biomorphic silicon carbide ceramics coated with hydroxyapatite as prospective materials for bone implants.

    PubMed

    Gryshkov, Oleksandr; Klyui, Nickolai I; Temchenko, Volodymyr P; Kyselov, Vitalii S; Chatterjee, Anamika; Belyaev, Alexander E; Lauterboeck, Lothar; Iarmolenko, Dmytro; Glasmacher, Birgit

    2016-11-01

    Porous and cytocompatible silicon carbide (SiC) ceramics derived from wood precursors and coated with bioactive hydroxyapatite (HA) and HA-zirconium dioxide (HA/ZrO2) composite are materials with promising application in engineering of bone implants due to their excellent mechanical and structural properties. Biomorphic SiC ceramics have been synthesized from wood (Hornbeam, Sapele, Tilia and Pear) using a forced impregnation method. The SiC ceramics have been coated with bioactive HA and HA/ZrO2 using effective gas detonation deposition approach (GDD). The surface morphology and cytotoxicity of SiC ceramics as well as phase composition and crystallinity of deposited coatings were analyzed. It has been shown that the porosity and pore size of SiC ceramics depend on initial wood source. The XRD and FTIR studies revealed the preservation of crystal structure and phase composition of in the HA coating, while addition of ZrO2 to the initial HA powder resulted in significant decomposition of the final HA/ZrO2 coating and formation of other calcium phosphate phases. In turn, NIH 3T3 cells cultured in medium exposed to coated and uncoated SiC ceramics showed high re-cultivation efficiency as well as metabolic activity. The recultivation efficiency of cells was the highest for HA-coated ceramics, whereas HA/ZrO2 coating improved the recultivation efficiency of cells as compared to uncoated SiC ceramics. The GDD method allowed generating homogeneous HA coatings with no change in calcium to phosphorus ratio. In summary, porous and cytocompatible bio-SiC ceramics with bioactive coatings show a great promise in construction of light, robust, inexpensive and patient-specific bone implants for clinical application.

  18. Bioactivity and biocompatibility of hydroxyapatite-based bioceramic coatings on zirconium by plasma electrolytic oxidation.

    PubMed

    Aktuğ, Salim Levent; Durdu, Salih; Yalçın, Emine; Çavuşoğlu, Kültigin; Usta, Metin

    2017-02-01

    In the present work, hydroxyapatite (HAP)-based plasma electrolytic oxide (PEO) coatings were produced on zirconium at different current densities in a solution containing calcium acetate and β-calcium glycerophosphate by a single step. The phase structure, surface morphology, functional groups, thickness and roughness of the coatings were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), attenuated total reflectance-Fourier transform infrared spectroscopy (ATR-FTIR), eddy current method and surface profilometer, respectively. The phases of cubic-zirconia, calcium zirconate and HAP were detected by XRD. The amount of HAP and calcium zirconate increased with increasing current density. The surface of the coatings was very porous and rough. Moreover, bioactivity and biocompatibility of the coatings were analyzed in vitro immersion simulated body fluid (SBF) and MTT (3-(4,5-dimethyl thiazol-2yl)-2,5-diphenyl tetrazolium bromide) assay, hemolysis assay and bacterial formation. The apatite-forming ability of the coatings was evaluated after immersion in SBF up to 28days. After immersion, the bioactivity of HAP-based coatings on zirconium was greater than the ones of uncoated zirconium and zirconium oxide-based surface. The bioactivity of PEO surface on zirconium was significantly improved under SBF conditions. The bacterial adhesion of the coatings decreased with increasing current density. The bacterial adhesion of the coating produced at 0.370A/cm(2) was minimum compared to uncoated zirconium coated at 0.260 and 0.292A/cm(2). The hemocompatibility of HAP-based surfaces was improved by PEO. The cell attachment and proliferation of the PEO coatings were better than the one of uncoated zirconium according to MTT assay results.

  19. Mechanisms of enhanced osteoblast gene expression in the presence of hydroxyapatite coated iron oxide magnetic nanoparticles

    NASA Astrophysics Data System (ADS)

    Tran, Nhiem; Hall, Douglas; Webster, Thomas J.

    2012-11-01

    Hydroxyapatite (HA) coated iron oxide (Fe3O4) magnetic nanoparticles have been shown to enhance osteoblast (bone forming cells) proliferation and osteoblast differentiation into calcium depositing cells (through increased secretion of alkaline phosphatase, collagen and calcium deposition) compared to control samples without nanoparticles. Such nanoparticles are, thus, very promising for numerous orthopedic applications including magnetically directed osteoporosis treatment. The objective of the current study was to elucidate the mechanisms of the aforementioned improved osteoblast responses in the presence of HA coated Fe3O4 nanoparticles. Results demonstrated large amounts of fibronectin (a protein known to increase osteoblast functions) adsorption on HA coated Fe3O4 nanoparticles. Specifically, fibronectin adsorption almost doubled when HA coated Fe3O4 nanoparticle concentrations increased from 12.5 to 100 μg ml-1, and from 12.5 to 200 μg ml-1, a four fold increase was observed. Results also showed greater osteoblast gene regulation (specifically, osteocalcin, type I collagen and cbfa-1) in the presence of HA coated Fe3O4 nanoparticles. Collectively, these results provide a mechanism for the observed enhanced osteoblast functions in the presence of HA coated iron oxide nanoparticles, allowing their further investigation for a number of orthopedic applications.

  20. Thermal Spraying of Bioactive Polymer Coatings for Orthopaedic Applications

    NASA Astrophysics Data System (ADS)

    Chebbi, A.; Stokes, J.

    2012-06-01

    Flame sprayed biocompatible polymer coatings, made of biodegradable and non-biodegradable polymers, were investigated as single coatings on titanium and as top coatings on plasma sprayed Hydroxyapatite. Biocompatible polymers can act as drug carriers for localized drug release following implantation. The polymer matrix consisted of a biodegradable polymer, polyhydroxybutyrate 98%/ polyhydroxyvalerate 2% (PHBV) and a non-biodegradable polymer, polymethylmethacrylate (PMMA). Screening tests were performed to determine the suitable range of spraying parameters, followed by a Design of Experiments study to determine the effects of spraying parameters on coating characteristics (thickness, roughness, adhesion, wettability), and to optimize the coating properties accordingly. Coatings characterization showed that optimized flame sprayed biocompatible polymers underwent little chemical degradation, did not produce acidic by-products in vitro, and that cells proliferated well on their surface.

  1. The abrasive wear of plasma sprayed nanoscale tungsten carbide-cobalt (WC-Co)

    NASA Astrophysics Data System (ADS)

    Tewksbury, Graham Alfred

    Thermal spray coatings composed of a variety of carbide sizes and cobalt contents were sprayed with a high energy plasma spray system. The size of the carbides used fell into three rough groupings, micrometer scale carbides (1--2 mum), submicrometer (700--300 nm), and nanoscale (≈100 nm). The feedstock powder was evaluated in terms of their size distribution, external morphology, internal morphology, and initial carbide size. Two different fixtures were used in spraying to evaluate the effect of cooling rate on the wear resistance of the coatings. The microstructures of the sprayed coatings were examined using optical metallography, SEM, FESEM, TEM, XRD and chemical analysis. The coatings were evaluated in low stress abrasive wear by the ASTM G-65 Dry Sand Rubber Wheel test. Furthermore, the porosity and hardness of the coatings were evaluated. The cobalt content was found to be the predominant influence on the wear rate of the coatings. The decrease in the carbide size was not found to effect the wear rate of the coatings. Coatings sprayed on the 'hot' fixture were found to have slightly improved wear resistance as compared to coatings sprayed on the 'cold' fixture. The wear rates of the coatings were found to be a function of the WC/Co volume ratio.

  2. Influence of Silver-hydroxyapatite Nanocomposite Coating on Biofilm Formation of Joint Prosthesis and Its Mechanism

    PubMed Central

    Zhao, L; Ashraf, MA

    2015-01-01

    ABSTRACT Background: The main reason for biomaterial related refractory infections is biofilm formation caused by bacterial adhesion on the surface of materials. Silver-hydroxyapatite (Ag/HA) nanocomposite coating can inhibit the formation of biofilm, but its mechanism is not clear. Material and Method: In order to clarify the mechanism, the amounts of biofilm on the Ag/HA composite coating and HA coating were determined, the release rates of silver nanoparticles in simulated body fluid (SBF) were detected by atomic absorption spectrometry, and the expression values of atlE, fbe, sap, iapB genes of Staphylococcus aureus were studied when they grew on Ag/HA composite coating and HA coating. Results: The amount of the biofilm on the Ag/HA composite coating was significantly less than that on the HA coating, and the bacterial adhesion was decreased. The silver nanoparticles were released continuously in SBF and the release rate decreased gradually with time. The expression values of atlE, fbe and sap were high in the initial stage of adhesion and the expression value of iapB was high in the colonies-gathering stage in the control group, but they were all significantly inhibited in the presence of Ag. Conclusion: These results indicated that the main antibacterial effect of Ag/HA composite coating was achieved by the release of silver nanoparticles. The addition of Ag inhibited the expression of genes related to biofilm formation, which in turn inhibited the formation of biofilms. This provided theoretical support for the clinical application of Ag/HA composite coating. PMID:27400164

  3. In vitro osteoblast-like cell proliferation on nano-hydroxyapatite coatings with different morphologies on a titanium-niobium shape memory alloy.

    PubMed

    Xiong, Jianyu; Li, Yuncang; Hodgson, Peter D; Wen, Cui'e

    2010-12-01

    The morphology of nanomaterials significantly affects their physical, chemical, and biological properties. In the present study, nano-hydroxyapatite coatings with different morphologies were produced on the surface of a titanium-niobium shape memory alloy via a hydrothermal process. The effect of the nano-hydroxyapatite coatings on the in vitro proliferation of SaOS-2 osteoblast-like cells was investigated. Factors including crystallinity, surface micro-roughness, and surface energy of the nano-hydroxyapatite coatings were discussed. Results show that in vitro proliferation of the osteoblast-like cells was significantly enhanced on the nano-hydroxyapatite-coated titanium-niobium alloy compared to the titanium-niobium alloy without coating. The cell numbers on the nano-hydroxyapatite-coated titanium-niobium alloy changed consistently with the surface energy of the hydroxyapatite coatings. This study suggests that surface energy as a characteristic parameter influencing the in vitro proliferation of osteoblast-like cells was predominant over the crystallinity and surface micro-roughness of the nano-hydroxyapatite coatings.

  4. Controlling the electrodeposition, morphology and structure of hydroxyapatite coating on 316L stainless steel.

    PubMed

    Thanh, Dinh Thi Mai; Nam, Pham Thi; Phuong, Nguyen Thu; Que, Le Xuan; Anh, Nguyen Van; Hoang, Thai; Lam, Tran Dai

    2013-05-01

    Hydroxyapatite (HAp) coatings were prepared on 316L stainless steel (316LSS) substrates by electrochemical deposition in the solutions containing Ca(NO3)2·4H2O and NH4H2PO4 at different electrolyte concentrations. Along with the effect of precursor concentration, the influence of temperature and H2O2 content on the morphology, structure and composition of the coating was thoroughly discussed with the help of X-ray diffraction (XRD), Scanning electron microscopy (SEM), Fourier transform infrared (FTIR) spectra. The in vitro tests in simulated body fluids (SBF) were carried out and then the morphological and structural changes were estimated by SEM and electrochemical techniques (open circuit potential, polarization curves, Nyquist and Bode spectra measurements). Being simple and cost-effective, this method is advantageous for producing HAp implant materials with good properties/characteristics, aiming towards in vivo biomedical applications.

  5. Surface modification of yttria stabilized zirconia via polydopamine inspired coating for hydroxyapatite biomineralization

    NASA Astrophysics Data System (ADS)

    Zain, Norhidayu Muhamad; Hussain, Rafaqat; Kadir, Mohammed Rafiq Abdul

    2014-12-01

    Yttria stabilized zirconia (YSZ) has been widely used as biomedical implant due to its high strength and enhanced toughening characteristics. However, YSZ is a bioinert material which constrains the formation of chemical bonds with bone tissue following implantation. Inspired by the property of mussels, the surface of YSZ ceramics was functionalized by quinone-rich polydopamine to facilitate the biomineralization of hydroxyapatite. YSZ discs were first immersed in 2 mg/mL of stirred or unstirred dopamine solution at either 25 or 37 °C. The samples were then incubated in 1.5 simulated body fluid (SBF) for 7d. The effect of coating temperature for stirred and unstirred dopamine solutions during substrate grafting was investigated on the basis of chemical compositions, wettability and biomineralization of hydroxyapatite on the YSZ functionalized surface. The results revealed that the YSZ substrate grafted at 37 °C in stirred solution of dopamine possessed significantly improved hydrophilicity (water contact angle of 44.0 ± 2.3) and apatite-mineralization ability (apatite ratio of 1.78). In summary, the coating temperature and stirring condition during grafting procedure affected the chemical compositions of the films and thus influenced the formation of apatite layer on the substrate during the biomineralization process.

  6. High temperature coatings for gas bearings

    NASA Technical Reports Server (NTRS)

    Murray, S. F.

    1969-01-01

    Aluminum oxide and nickel-chrome bonded chrome carbide coatings enhance the performance of gas bearings at temperatures up to 1400 degrees F. A plasma-sprayed aluminum-oxide coating is applied to the bearing surface and a plasma- sprayed 25 percent nickel-chrome bonded chrome carbide coating is applied to the journal surface.

  7. Interaction Studies of Ceramic Vacuum Plasma Spraying for the Melting Crucible Materials

    SciTech Connect

    Jong Hwan Kim; Hyung Tae Kim; Yoon Myung Woo; Ki Hwan Kim; Chan Bock Lee; R. S. Fielding

    2013-10-01

    Candidate coating materials for re-usable metallic nuclear fuel crucibles, TaC, TiC, ZrC, ZrO2, and Y2O3, were plasmasprayed onto a niobium substrate. The microstructure of the plasma-sprayed coatings and thermal cycling behavior were characterized, and U-Zr melt interaction studies were carried out. The TaC and Y2O3 coating layers had a uniform thickness, and high density with only a few small closed pores showing good consolidation, while the ZrC, TiC, and ZrO2 coatings were not well consolidated with a considerable amount of porosity. Thermal cycling tests showed that the adhesion of the TiC, ZrC, and ZrO2 coating layers with niobium was relatively weak compared to the TaC and Y2O3 coatings. The TaC and Y2O3 coatings had better cycling characteristics with no interconnected cracks. In the interaction studies, ZrC and ZrO2 coated rods showed significant degradations after exposure to U-10 wt.% Zr melt at 1600 degrees C for 15 min., but TaC, TiC, and Y2O3 coatings showed good compatibility with U-Zr melt.

  8. Antibacterial and bioactivity of silver substituted hydroxyapatite/TiO2 nanotube composite coatings on titanium

    NASA Astrophysics Data System (ADS)

    Yan, Yajing; Zhang, Xuejiao; Huang, Yong; Ding, Qiongqiong; Pang, Xiaofeng

    2014-09-01

    Hydroxyapatite doped with Ag+ ions (AgHAp) was synthesized via electrochemical deposition method on anodized titanium. The samples were characterized via X-ray diffraction, Fourier transform infrared spectrum analysis, X-Ray photoelectron spectroscopy and scanning electron microscopy to investigate the phase formation and microstructure of the samples. Highly ordered TiO2 nanotubes with a diameter of 100 nm were successfully synthesized, and the AgHAp coating was deposited on the TiO2 nanotubes, which has a thickness of about 17.7 ± 1.5 μm. Moreover, silver was uniformly-distributed on the nanotubes. Bioactivity and electrochemical studies were performed for the AgHAp-coated TiO2 in a simulated body fluid, where significant good bioactivity and corrosion resistance were exhibited. The antibacterial and osteoblast cell adhesion tests in vitro revealed that the AgHAp coating with 2.03 wt% silver had significant antibacterial and osteogenic properties. Thus, the AgHAp coating was regarded as a promising candidate for coating orthopedic implants.

  9. Hydroxyapatite/titania sol-gel coatings on titanium-zirconium alloy for biomedical applications.

    PubMed

    Wen, C E; Xu, W; Hu, W Y; Hodgson, P D

    2007-05-01

    A simple sol-gel method was developed for hydroxyapatite/titania (HA/TiO(2)) coatings on non-toxic titanium-zirconium (TiZr) alloy for biomedical applications. The HA/TiO(2)-coated TiZr alloy displayed excellent bioactivity when soaked in a simulated body fluid (SBF) for an appropriate period. Differential scanning calorimetry, thermogravimetric analysis, X-ray diffraction and scanning electron microscopy-energy dispersive spectrometry were used to characterize the phase transformations and the surface structures and to assess the in vitro tests. The HA/TiO(2) layers were spin-coated on the surface of TiZr alloy at a speed of 3000rpm for 15s, followed by a heat treatment at 600 degrees C for 20min in an argon atmosphere sequentially. The TiO(2) layer exhibited a cracked surface and an anatase structure and the HA layer displayed a uniform dense structure. Both the TiO(2) and HA layers were 25microm thick, and the total thickness of the HA/TiO(2) coatings was 50microm. The TiZr alloy after the above HA/TiO(2) coatings displayed excellent bone-like apatite-forming ability when soaked in SBF and can be anticipated to be a promising load-bearing implant material.

  10. Electrophoretic deposition of nanostructured hydroxyapatite coating on AZ91 magnesium alloy implants with different surface treatments

    NASA Astrophysics Data System (ADS)

    Rojaee, Ramin; Fathi, Mohammadhossein; Raeissi, Keyvan

    2013-11-01

    Bio-absorbable magnesium (Mg) based alloys have been introduced as innovative orthopedic implants during recent years. It has been specified that rapid degradation of Mg based alloys in physiological environment should be restrained in order to be utilized in orthopedic trauma fixation and vascular intervention. In this developing field of healthcare materials, micro-arc oxidation (MAO), and MgF2 conversion coating were exploited as surface pre-treatment of AZ91 magnesium alloy to generate a nanostructured hydroxyapatite (n-HAp) coating via electrophoretic deposition (EPD) method. X-ray diffraction (XRD), scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FT-IR), and transmission electron microscopy (TEM) techniques were used to characterize the obtained powder and coatings. The potentiodynamic polarization tests were carried out to evaluate the corrosion behavior of the coated and uncoated specimens, and in vitro bioactivity evaluation were performed in simulated body fluid. Results revealed that the MAO/n-HAp coated AZ91 Mg alloy samples with a rough topography and lower corrosion current density leads to a lower Mg degradation rate accompanied by high bioactivity.

  11. In situ synthesis of mesoporous polyvinyl alcohol/hydroxyapatite composites for better biomedical coating adhesion

    NASA Astrophysics Data System (ADS)

    Hussain, Riaz; Tabassum, Sobia; Gilani, Mazhar Amjad; Ahmed, Ejaz; Sharif, Ahsan; Manzoor, Faisal; Shah, Asma Tufail; Asif, Anila; Sharif, Faiza; Iqbal, Farasat; Siddiqi, Saadat Anwar

    2016-02-01

    Hydroxyapatite (HA) shows diverse biomedical applications as bone filler and coating material for metal implants to enhance osteoconduction. Four different PVAHA composites were synthesized in situ by an economical co-precipitation wet methodology. The FTIR spectra of PVAHA composites showed characteristic signals of HA and PVA. The BET surface area of PVAHA composites were in range of 41.3-63.7 m2/g. The composites showed type IV nitrogen adsorption/desorption isotherm, a characteristic for mesoporous material. The pore diameter range (6.3-8.1 nm) of PVAHA composites also confirmed their mesoporous nature. The Barrett-Joyner-Halenda (BJH) pore size distribution curves indicated a narrow pore size distribution. To obtain a homogeneous crack free coating with EPD on stainless steel (SS) plates, different parameters such as PVA percentages in PVAHA composites, solvent, deposition time and voltage were optimized. The PVAHA composites were stable after EPD as confirmed by FTIR spectra recorded before and after EPD. The SEM images of the coating showed a homogeneous morphology. The thickness of the coating was controlled by varying voltage and time. The best results were obtained with c-PVAHA composite at 30 volts for 5-10 min and current density was around 4.5 to 5 mA. The adhesion strength of c-PVAHA coating was measured by using ASTM standard F1044-99. The average value was approximately 9.328 ± 1.58 MPa.

  12. Antibacterial chitosan coating on nano-hydroxyapatite/polyamide66 porous bone scaffold for drug delivery.

    PubMed

    Huang, Di; Zuo, Yi; Zou, Qin; Zhang, Li; Li, Jidong; Cheng, Lin; Shen, Juan; Li, Yubao

    2011-01-01

    This study describes a new drug-loaded coating scaffold applied in infection therapy during bone regeneration. Chitosan (CS) containing antibacterial berberine was coated on a nano-hydroxyapatite/polyamide66 (n-HA/PA66) scaffold to realize bone regeneration together with antimicrobial properties. The porous scaffold was fabricated using the phase-inversion method with a porosity of about 84% and macropore size of 400-600 μm. The morphology, mechanical properties and drug-release behavior were investigated at different ratios of chitosan to berberine. The results show that the elastic modulus and compressive strength of the coated scaffolds were improved to 35.4 MPa and 1.7 MPa, respectively, about 7 times and 3 times higher than the uncoated scaffolds. After a burst release of berberine within the first 3 h in PBS solution, a continuous berberine release can last 150 h, which is highly dependent on the coating concentration and suitable for antibacterial requirement of orthopaedic surgery. The bactericidal test confirms a strong antibiotic effect of the delivery system and the minimum inhibitory concentration of the drug is 0.02 mg/ml. Moreover, in vitro biological evaluation demonstrates that the coating scaffolds act as a good matrix for MG63 adhesion, crawl, growth and proliferation, suggesting that the antibacterial delivery system has no cytotoxicity. We expect the drug-delivery system to have a potential application in bone regeneration or defect repair.

  13. Mechanical behaviour of cp-magnesium with duplex hydroxyapatite and PEO coatings.

    PubMed

    Gao, Yonghao; Yerokhin, Aleksey; Matthews, Allan

    2015-04-01

    Hydroxyapatite-magnesia coatings were formed on cp-magnesium by plasma electrolytic oxidation (PEO) followed by cathodic electrodeposition (CED). The static tensile and cyclic fatigue performance of the coated samples were investigated. The cracking behaviour of the coatings during the tensile tests was studied by fracture analysis. The effects of the surface treatment on the fatigue performance of the magnesium substrate were addressed. Tensile strength of cp-Mg was not significantly affected, whereas the fatigue performance was improved by the PEO+CED coatings in the low-cycle region, possibly due to compressive residual stress induced to the metal substrate by the surface treatment. However, reduced fatigue strength was observed in the high-cycle region, which might be attributed to the defects at the coating/substrate interface produced during the surface modification. The in vitro corrosion reduced the fatigue strength in both the low- and high-cycle regions. Finally, the applicability of surface engineered magnesium for biomedical applications was demonstrated from the mechanical standpoint.

  14. Biomimetic helical rosette nanotubes and nanocrystalline hydroxyapatite coatings on titanium for improving orthopedic implants.

    PubMed

    Zhang, Lijie; Chen, Yupeng; Rodriguez, Jose; Fenniri, Hicham; Webster, Thomas J

    2008-01-01

    Natural bone consists of hard nanostructured hydroxyapatite (HA) in a nanostructured protein-based soft hydrogel template (ie, mostly collagen). For this reason, nanostructured HA has been an intriguing coating material on traditionally used titanium for improving orthopedic applications. In addition, helical rosette nanotubes (HRNs), newly developed materials which form through the self-assembly process of DNA base pair building blocks in body solutions, are soft nanotubes with a helical architecture that mimics natural collagen. Thus, the objective of this in vitro study was for the first time to combine the promising attributes of HRNs and nanocrystalline HA on titanium and assess osteoblast (bone-forming cell) functions. Different sizes of nanocrystalline HA were synthesized in this study through a wet chemical precipitation process following either hydrothermal treatment or sintering. Transmission electron microscopy images showed that HRNs aligned with nanocrystalline HA, which indicates a high affinity between both components. Some of the nanocrystalline HA formed dense coatings with HRNs on titanium. More importantly, results demonstrated enhanced osteoblast adhesion on the HRN/nanocrystalline HA-coated titanium compared with conventional uncoated titanium. Among all the HRN/nanocrystalline HA coatings tested, osteoblast adhesion was the greatest when HA nanometer particle size was the smallest. In this manner, this study demonstrated for the first time that biomimetic HRN/nanocrystalline HA coatings on titanium were cytocompatible for osteoblasts and, thus, should be further studied for improving orthopedic implants.

  15. Effects of hydroxyapatite coating on survival of an uncemented femoral stem

    PubMed Central

    2011-01-01

    Background and purpose Hydroxyapatite (HA) is widely used as a coating for uncemented total hip arthroplasty components. This has been suggested to improve implant ingrowth and long-term stability. However, the evidence behind the use of HA coating on femoral stems is ambiguous. We investigated survival of an uncemented, tapered titanium femoral stem that was available either with or without HA coating (Bi-Metric). Patients and methods The stem had been used in 4,772 total hip arthroplasties (THAs) in 4,169 patients registered in the Swedish Hip Arthroplasty Register between 1992 and 2009. 59% of the stems investigated were coated with HA and 41% were uncoated. Kaplan-Meier survival analysis and a Cox regression model with adjustment for age, sex, primary diagnosis, and the type of cup fixation were used to calculate survival rates and adjusted risk ratios (RRs) of the risk of revision for various reasons. Results The 10-year survival rates of the HA-coated version and the uncoated version were about equal when we used revision for any reason as the endpoint: 98% (95% CI: 98–99) and 98% (CI: 97–99), respectively. A Cox regression model adjusting for the covariates mentioned above showed that the presence of HA coating did not have any influence on the risk of stem revision for any reason (RR = 1.0, 95% CI: 0.6–1.6) or due to aseptic loosening (RR = 0.5, CI: 0.2–1.5). There was no effect of HA coating on the risk of stem revision due to infection, dislocation, or fracture. Interpretation The uncemented Bi-Metric stem showed excellent 10-year survival. Our findings do not support the use of HA coating on this stem to enhance implant survival. PMID:21751858

  16. The effect of processing parameters on plasma sprayed beryllium for fusion applications

    SciTech Connect

    Castro, R.G.; Stanek, P.W.; Jacobson, L.A.; Cowgill, D.F.; Snead, L.L.

    1993-10-01

    Plasma spraying is being investigated as a potential coating technique for applying thin (0.1--5mm) layers of beryllium on plasma facing surfaces of blanket modules in ITER and also as an in-situ repair technique for repairing eroded beryllium surfaces in high heat flux divertor regions. High density spray deposits (>98% of theoretical density) of beryllium will be required in order to maximize the thermal conductivity of the beryllium coatings. A preliminary investigation was done to determine the effect of various processing parameters (particle size, particle morphology, secondary gas additions and reduced chamber pressure) on the as-deposited density of beryllium. The deposits were made using spherical beryllium feedstock powder which was produced by centrifugal atomization at Los Alamos National Laboratory (LANL). Improvements in the as-deposited densities and deposit efficiencies of the beryllium spray deposits will be discussed along with the corresponding thermal conductivity and outgassing behavior of these deposits.

  17. Plasma Spray-CVD: A New Thermal Spray Process to Produce Thin Films from Liquid or Gaseous Precursors

    NASA Astrophysics Data System (ADS)

    Gindrat, M.; Höhle, H.-M.; von Niessen, K.; Guittienne, Ph.; Grange, D.; Hollenstein, Ch.

    2011-06-01

    New dedicated coating processes which are based on the well-known LPPS™ technology but operating at lower work pressure (100 Pa) are being actively developed. These hybrid technologies contribute to improve the efficiencies in the turbine industry such as aero-engines and land-based gas turbines. They also have a great potential in the domain of new energy concepts in applications like Solid Oxide Fuel Cells, membranes, and photovoltaic with the adoption of new ways of producing coatings by thermal spray. Such processes include Plasma Spray-Thin Film (PS-TF) which gives the possibility to coat thin and dense layers from splats through a classical thermal spray approach but at high velocities (400-800 m/s) and enthalpy (8000-15000 kJ/kg). Plasma Spray-PVD (PS-PVD) which allows producing thick columnar-structured Thermal Barrier Coatings (100-300 μm) from the vapor phase with the employment of the high enthalpy gun and specific powder feedstock material. On the other hand, the Plasma Spray-CVD (PS-CVD) process uses modified conventional thermal spray components operated below 100 Pa which allows producing CVD-like coatings (<1-10 μm) at higher deposition rates using liquid or gaseous precursors as feedstock material. The advantages of such thermal spray-enhanced CVD processes are the high ionization degree and high throughput for the deposition of thin layers. In this article, we present an overview of the possibilities and limitations encountered while producing thin film coatings using liquid and gaseous precursors with this new type of low pressure plasma spray equipment and point out the challenges faced to obtain efficient injection and mixing of the precursors in the plasma jet. In particular, SiO x thin films from Hexamethyldisiloxane (HMDSO or C6H18OSi2) can be deposited on wafers at deposition rates of up to 35 nm/s at an efficiency of about 50%. The process was also used for producing metal oxide coatings (Al2O3, ZnO, and SnO2) by evaporating different

  18. Flow characteristic of in-flight particles in supersonic plasma spraying process

    NASA Astrophysics Data System (ADS)

    Wei, Pei; Wei, Zhengying; Zhao, Guangxi; Du, Jun; Bai, Y.

    2016-09-01

    In this paper, a computational model based on supersonic plasma spraying (SAPS) is developed to describe the plasma jet coupled with the injection of carrier gas and particles for SAPS. Based on a high-efficiency supersonic spraying gun, the 3D computational model of spraying gun was built to study the features of plasma jet and its interactions with the sprayed particles. Further the velocity and temperature of in-flight particles were measured by Spray Watch 2i, the shape of in-flight particles was observed by scanning electron microscope. Numerical results were compared with the experimental measurements and a good agreement has been achieved. The flight process of particles in plasma jet consists of three stages: accelerated stage, constant speed stage and decelerated stage. Numerical and experimental indicates that the H2 volume fraction in mixture gas of Ar + H2 should keep in the range of 23-26 %, and the distance of 100 mm is the optimal spraying distance in Supersonic atmosphere plasma spraying. Particles were melted and broken into small child particles by plasma jet and the diameters of most child particles were less than 30 μm. In general, increasing the particles impacting velocity and surface temperature can decrease the coating porosity.

  19. A novel silica nanotube reinforced ionic incorporated hydroxyapatite composite coating on polypyrrole coated 316L SS for implant application.

    PubMed

    Prem Ananth, K; Joseph Nathanael, A; Jose, Sujin P; Oh, Tae Hwan; Mangalaraj, D

    2016-02-01

    An attempt has been made to deposit a novel smart ion (Sr, Zn, Mg) substituted hydroxyapatite (I-HAp) and silica nanotube (SiNTs) composite coatings on polypyrrole (PPy) coated surgical grade 316L stainless steel (316L SS) to improve its biocompatibility and corrosion resistance. The I-HAp/SiNTS/PPy bilayer coating on 316L SS was prepared by electrophoretic deposition technique. Potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) studies were carried out. These results confirmed the significant improvement of the corrosion resistance of the 316L SS alloy by the I-HAp/SiNTs/PPy bilayer composite coating. The adhesion strength and hardness test confirmed the anticipated mechanical properties of the composite. A low contact angle value revealed the hydrophilic nature. Inductively coupled plasma-atomic emission spectroscopy (ICP-AES) was used for the leach out analysis of the samples. Added to this, the bioactivity of the composite was analyzed by observing the apatite formation in the SBF solution for 7, 14, 21 and 28days of incubation. An enhancement of in vitro osteoblast attachment and cell viability was observed, which could lead to the optimistic orthopedic and dental applications.

  20. Osteoblastic cell attachment to hydroxyapatite-coated implant surfaces in vitro.

    PubMed

    Chang, Y L; Stanford, C M; Wefel, J S; Keller, J C

    1999-01-01

    Hydroxyapatite (HA) used as a coating for implants can exhibit varying levels of interaction with the biologic environment. The crystallinity of the HA-based coating has been shown to control the rate of dissolution and appears to play a role in the initial cellular interaction with the implant surfaces. An osteoblastic cell attachment assay was employed to examine the cell attachment to untreated and pretreated (pH 5.2, 24 hours) titanium and HA coatings of low (50%), medium (75%), and high (90%) crystallinity. A slightly higher percentage of cell attachment (%CA) was found on untreated and pretreated HA surfaces as compared to the titanium surface. No significant difference could be found in the %CA between the 3 levels of crystallinity. However, higher levels of %CA were observed on pretreated HA surfaces than on untreated HA surfaces (t test, P < .05). Elevated calcium and phosphate levels in culture medium did not have any effect on cell attachment. Scanning electron microscopic examinations revealed surface degradation of the HA coating following pretreatment in the simulated inflammatory media (pH 5.2, 24 hours). The results suggest that the altered surface topography may influence the initial cell attachment to HA surfaces.

  1. Reinforced Pulsed Laser-Deposited Hydroxyapatite Coating on 316 Stainless Steel

    NASA Astrophysics Data System (ADS)

    Bajpai, Shubhra; Gupta, Ankur; Pradhan, Siddhartha Kumar; Mandal, Tapendu; Balani, Kantesh

    2014-10-01

    Hydroxyapatite (HA) is a widely used bioceramic known for its chemical similarity with that of bone and teeth (Ca/P ratio of 1.67). But, owing to its extreme brittleness, α-Al2O3 is reinforced with HA and processed as a coating via pulsed laser deposition (PLD). Reinforcement of α-Al2O3 (50 wt.%) in HA via PLD on 316L steel substrate has shown modulus increase by 4% and hardness increase by 78%, and an improved adhesion strength of 14.2 N (improvement by 118%). Micro-scratching has shown an increase in the coefficient-of-friction from 0.05 (pure HA) to 0.17 (with 50 wt.% Al2O3) with enhancement in the crack propagation resistance (CPR) up to 4.5 times. Strong adherence of PLD HA-Al2O3 coatings (~4.5 times than that of HA coating) is attributed to efficient release of stored tensile strain energy (~17 × 10-3 J/m2) in HA-Al2O3 composites, making it a potential damage-tolerant bone-replacement surface coating.

  2. Electrophoretic deposition of hydroxyapatite-CaSiO3-chitosan composite coatings.

    PubMed

    Pang, Xin; Casagrande, Travis; Zhitomirsky, Igor

    2009-02-15

    Electrophoretic deposition (EPD) method has been developed for the fabrication of hydroxyapatite (HA)-CaSiO(3) (CS)-chitosan composite coatings for biomedical applications. The use of chitosan enabled the co-deposition of HA and CS particles and offered the advantage of room temperature processing of composite materials. The coating composition was varied by the variation of HA and CS concentrations in the chitosan solutions. Cathodic deposits were obtained as HA-CS-chitosan monolayers, HA-chitosan/chitosan multilayers or functionally graded materials (FGM) containing HA-chitosan and CS-chitosan layers of different composition. The thickness of the individual layers was varied in the range of 0.1-20 microm. The deposition yield was studied at different experimental conditions and compared with the results of modeling. It was shown that the moving boundary model for the two component system can explain the non-linear increase in the deposition yield with increasing HA concentration in chitosan solutions. The obtained coatings were studied by thermogravimetric analysis (TGA), differential thermal analysis (DTA) and scanning electron microscopy (SEM). Potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) studies showed that these coatings provided corrosion protection of stainless steel substrates in Ringer's physiological solution. The deposition mechanism and kinetics of deposition have been discussed.

  3. Electrochemical Evaluation of Pyrite Films Prepared by Plasma Spraying

    SciTech Connect

    Guidotti, R.A.; Reinhardt, F.W.

    1998-10-30

    Thermally activated batteries use electrodes that are typically fabricated by cold pressing of powder. In the LiSi/FeS2 system, natural (mineral) pyrite is used for the cathode. In an effort to increase the energy density and specific energy of these batteries, flame and plasma spraying to form thin films of pyrite cathodes were evaluated. The films were deposited on a 304 stainless steel substrate (current collector) and were characterized by scanning electron microscopy and x-ray dlfllaction. The films were electrochemically tested in single cells at 5000C and the petiormance compared to that of standard cells made with cold-pressed powders. The best results were obtained with material deposited by de-arc plasma spraying with a proprietq additive to suppress thermal decomposion of the pyrite.

  4. Characterization of Plasma Sprayed Beryllium ITER First Wall Mockups

    SciTech Connect

    Castro, Richard G.; Vaidya, Rajendra U.; Hollis, Kendall J.

    1997-12-31

    ITER first wall beryllium mockups, which were fabricated by vacuum plasma spraying the beryllium armor, have survived 3000 thermal fatigue cycles at 1 MW/sq m without damage during high heat flux testing at the Plasma Materials Test Facility at Sandia National Laboratory in New Mexico. The thermal and mechanical properties of the plasma sprayed beryllium armor have been characterized. Results are reported on the chemical composition of the beryllium armor in the as-deposited condition, the through thickness and normal to the through thickness thermal conductivity and thermal expansion, the four-point bend flexure strength and edge-notch fracture toughness of the beryllium armor, the bond strength between the beryllium armor and the underlying heat sink material, and ultrasonic C-scans of the Be/heat sink interface.

  5. Reduced graphene oxide-coated hydroxyapatite composites stimulate spontaneous osteogenic differentiation of human mesenchymal stem cells

    NASA Astrophysics Data System (ADS)

    Lee, Jong Ho; Shin, Yong Cheol; Jin, Oh Seong; Kang, Seok Hee; Hwang, Yu-Shik; Park, Jong-Chul; Hong, Suck Won; Han, Dong-Wook

    2015-07-01

    Human mesenchymal stem cells (hMSCs) have great potential as cell sources for bone tissue engineering and regeneration, but the control and induction of their specific differentiation into bone cells remain challenging. Graphene-based nanomaterials are considered attractive candidates for biomedical applications such as scaffolds in tissue engineering, substrates for SC differentiation and components of implantable devices, due to their biocompatible and bioactive properties. Despite the potential biomedical applications of graphene and its derivatives, only limited information is available regarding their osteogenic activity. This study concentrates upon the effects of reduced graphene oxide (rGO)-coated hydroxyapatite (HAp) composites on osteogenic differentiation of hMSCs. The average particle sizes of HAp and rGO were 1270 +/- 476 nm and 438 +/- 180 nm, respectively. When coated on HAp particulates, rGO synergistically enhanced spontaneous osteogenic differentiation of hMSCs, without hampering their proliferation. This result was confirmed by determining alkaline phosphatase activity and mineralization of calcium and phosphate as early and late stage markers of osteogenic differentiation. It is suggested that rGO-coated HAp composites can be effectively utilized as dental and orthopedic bone fillers since these graphene-based particulate materials have potent effects on stimulating the spontaneous differentiation of MSCs and show superior bioactivity and osteoinductive potential.Human mesenchymal stem cells (hMSCs) have great potential as cell sources for bone tissue engineering and regeneration, but the control and induction of their specific differentiation into bone cells remain challenging. Graphene-based nanomaterials are considered attractive candidates for biomedical applications such as scaffolds in tissue engineering, substrates for SC differentiation and components of implantable devices, due to their biocompatible and bioactive properties. Despite

  6. Investigations on the Nature of Ceramic Deposits in Plasma Spray-Physical Vapor Deposition

    NASA Astrophysics Data System (ADS)

    He, W.; Mauer, G.; Gindrat, M.; Wäger, R.; Vaßen, R.

    2017-01-01

    In Plasma Spray-Physical Vapor Deposition (PS-PVD) process, major fractions of the feedstock powder can be evaporated so that coatings are deposited mainly from the vapor phase. In this work, Computational Fluid Dynamics (CFD) results indicate that such evaporation occurs significantly in the plasma torch nozzle and even nucleation and condensation of zirconia is highly possible there. Experimental work has been performed to investigate the nature of the deposits in the PS-PVD process, in particular coatings from condensate vapor and nano-sized clusters produced at two spraying distances of 1000 mm and 400 mm. At long spraying distance, columns in the coatings have pyramidal tops and very sharp faceted microstructures. When the spraying distance is reduced to 400 mm, the tops of columns become relatively flat and a faceted structure is not recognizable. XRD patterns show obvious preferred orientations of (110) and (002) in the coatings sprayed at 400 mm but only limited texture in the coatings sprayed at 1000 mm. Meanwhile, a non-line of sight coating was also investigated, which gives an example for pure vapor deposition. Based on these analyses, a vapor and cluster depositions are suggested to further explain the formation mechanisms of high-quality columnar-structured PS-PVD thermal barrier coatings which have already shown excellent performance in cyclic lifetime test.

  7. Biocompatibility of a porous alumina ceramic scaffold coated with hydroxyapatite and bioglass.

    PubMed

    Kido, Hueliton Wilian; Ribeiro, Daniel Araki; de Oliveira, Poliani; Parizotto, Nivaldo Antônio; Camilo, Claudia Cristiane; Fortulan, Carlos Alberto; Marcantonio, Elcio; da Silva, Victor Hugo Pereira; Renno, Ana Claudia Muniz

    2014-07-01

    This study aimed to evaluate the osteointegration and genotoxic potential of a bioactive scaffold, composed of alumina and coated with hydroxyapatite and bioglass, after their implantation in tibias of rats. For this purpose, Wistar rats underwent surgery to induce a tibial bone defect, which was filled with the bioactive scaffolds. Histology analysis (descriptive and morphometry) of the bone tissue and the single-cell gel assay (comet) in multiple organs (blood, liver, and kidney) were used to reach this aim after a period of 30, 60, 90, and 180 days of material implantation. The main findings showed that the incorporation of hydroxyapatite and bioglass in the alumina scaffolds produced a suitable environment for bone ingrowth in the tibial defects and did not demonstrate any genotoxicity in the organs evaluated in all experimental periods. These results clearly indicate that the bioactive scaffolds used in this study present osteogenic potential and still exhibit local and systemic biocompatibility. These findings are promising once they convey important information about the behavior of this novel biomaterial in biological system and highlight its possible clinical application.

  8. A review of hydroxyapatite-based coating techniques: Sol-gel and electrochemical depositions on biocompatible metals.

    PubMed

    Asri, R I M; Harun, W S W; Hassan, M A; Ghani, S A C; Buyong, Z

    2016-04-01

    New promising techniques for depositing biocompatible hydroxyapatite-based coatings on biocompatible metal substrates for biomedical applications have continuously been exploited for more than two decades. Currently, various experimental deposition processes have been employed. In this review, the two most frequently used deposition processes will be discussed: a sol-gel dip coating and an electrochemical deposition. This study deliberates the surface morphologies and chemical composition, mechanical performance and biological responses of sol-gel dip coating as well as the electrochemical deposition for two different sample conditions, with and without coating. The review shows that sol-gel dip coatings and electrochemical deposition were able to obtain the uniform and homogeneous coating thickness and high adherent biocompatible coatings even in complex shapes. It has been accepted that both coating techniques improve bone strength and initial osseointegration rate. The main advantages and limitations of those techniques of hydroxyapatite-based coatings are presented. Furthermore, the most significant challenges and critical issues are also highlighted.

  9. Preparation and properties of in-situ growth of carbon nanotubes reinforced hydroxyapatite coating for carbon/carbon composites.

    PubMed

    Liu, Shoujie; Li, Hejun; Su, Yangyang; Guo, Qian; Zhang, Leilei

    2017-01-01

    Carbon nanotubes (CNTs) possess excellent mechanical properties for their role playing in reinforcement as imparting strength to brittle hydroxyapatite (HA) bioceramic coating. However, there are few reports relating to the in-situ grown carbon nanotubes reinforced hydroxyapatite (CNTs-HA) coating. Here we demonstrate the potential application in reinforcing biomaterials by an attempt to use in-situ grown of CNTs strengthen HA coating, using a combined method composited of injection chemical vapor deposition (ICVD) and pulsed electrodeposition. The microstructure, phases and chemical compositions of CNTs-HA coatings were characterized by various advanced methods. The scanning electron microscopy (SEM) images indicated that CNTs-HA coatings avoided the inhomogeneous dispersion of CNTs inside HA coating. The result show that the interfacial shear strength between CNTs-HA coating and the C/C composite matrix reaches to 12.86±1.43MPa. Potenitodynamic polarization and electrochemical impedance spectroscopy (EIS) studies show that the content of CNTs affects the corrosion resistance of CNTs-HA coating. Cell culturing and simulated body fluid test elicit the biocompatibility with living cells and bioactivity of CNTs-HA coatings, respectively.

  10. The Effect of Coating Thickness on Corrosion Resistance of Hydroxyapatite Coated Ti6Al4V and 316L SS Implants

    NASA Astrophysics Data System (ADS)

    Aksakal, B.; Gavgali, M.; Dikici, B.

    2010-08-01

    Hydroxyapatite (HAP) has been coated onto Ti6Al4V and 316L SS substrates by sol-gel method. The coating thicknesses for the analysis were about 40 and 72 μm. Adhesion and corrosion tests have been conducted on uncoated and HAP-coated substrates. The coatings were characterized by XRD, SEM, and adhesion analysis. The corrosion resistance was examined in vitro by potentiodynamic polarization technique in Ringer’s solution at room temperature. Electrochemical analysis indicated that the highest corrosion susceptibility was found on 72-μm-coated 316L SS, and the 40-μm HAP-coated Ti6Al4V showed the highest corrosion resistance. It was observed that the coating thickness was an effective parameter on both adhesion and corrosion resistance. It was shown that adhesion and corrosion resistance decreased with increasing coating thickness on both substrates.

  11. Effect of nano-hydroxyapatite coating on the osteoinductivity of porous biphasic calcium phosphate ceramics

    PubMed Central

    2014-01-01

    Background Porous biphasic calcium phosphate (BCP) ceramics exhibit good biocompatibility and bone conduction but are not inherently osteoinductive. To overcome this disadvantage, we coated conventional porous BCP ceramics with nano-hydroxyapatite (nHA). nHA was chosen as a coating material due to its high osteoinductive potential. Methods We used a hydrothermal deposition method to coat conventional porous BCP ceramics with nHA and assessed the effects of the coating on the physical and mechanical properties of the underlying BCP. Next, its effects on mesenchymal stem cell (MSC) attachment, proliferation, viability, and osteogenic differentiation were investigated. Results nHA formed a deposited layer on the BCP surface, and synthesized nHA had a rod-like shape with lengths ranging from ~50–200 nm and diameters from ~15–30 mm. The nHA coating did not significantly affect the density, porosity, flexural strength, or compressive strength of the underlying BCP (P > 0.1). Scanning electron microscopy showed MSC attachment to the scaffolds, with a healthy morphology and anchorage to nHA crystals via cytoplasmic processes. The densities of MSCs attached on BCP and nHA-coated BCP scaffolds were 62 ± 26 cells/mm2 and 63 ± 27 cells/mm2 (P > 0.1), respectively, after 1 day and 415 ± 62 cells/mm2 and 541 ± 35 cells/mm2 (P < 0.05) respectively, after 14 days. According to an MTT assay, MSC viability was higher on nHA-coated BCP scaffolds than on BCP scaffolds (P < 0.05). In addition, MSCs on nHA-coated BCP scaffolds produced more alkaline phosphatase, collagen type I, and osteocalcin than MSCs on BCP scaffolds (P < 0.05). Conclusions Our results demonstrate that BCP scaffolds coated with nHA were more conducive for MSC adhesion, proliferation, and osteogenic differentiation than conventional, uncoated BCP scaffolds, indicating that nHA coating can enhance the osteoinductive potential of BCP ceramics, making this material more

  12. Preparation of biomedical Ag incorporated hydroxyapatite/titania coatings on Ti6Al4V alloy by plasma electrolytic oxidation

    NASA Astrophysics Data System (ADS)

    Zhou, Lan; Lü, Guo-Hua; Mao, Fei-Fei; Yang, Si-Ze

    2014-03-01

    Nano-Ag incorporated hydroxyapatite/titania (HA/TiO2) coatings were deposited on Ti6Al4V substrates by the plasma electrolytic oxidation process. Compared with the substrate, the deposited coatings display attractive mechanical and biomedical properties. First, the coatings have stronger wear resistance and corrosion resistance. Second, they show a strong antibacterial ability. The mean vitality of the P. gingivalis on the coating surfaces is reduced to about 21%. Third, the coatings have good biocompatibility. The mean viability of the fibroblast cells on the coating surface is increased to about 130%. With these attractive properties, Ag incorporated HA/TiO2 coatings may be useful in the biomedical field.

  13. Design of a substrate heater for calcium hydroxyapatite coating by pulsed laser ablation

    SciTech Connect

    Chang, T.; Havstad, M.A.

    1995-07-24

    Calcium hydroxyapatite (HA) is the main chemical constituent of bone. When replacement hip joints are coated with this chemical, the body may be more likely to accept the artificial joint, forming new bone that bonds the joint to the original leg bone. HA deposited by laser ablation in vacuum adheres to the substrate better at high temperatures of up to 700 C. This heater should be capable of uniformly heating to 700 C a silicon disk 150 mm in diameter. The heater consists of two wire heating coils brazed into a disk of stainless steel, with tantalum shields on top and at the sides of the heater to minimize radiation loss. Three spring-rotation clamps at the bottom of the heater hold the substrate disk in place. This report describes the heater and how it was developed, including design evolution and thermal modeling. Also, detailed information about parts is discussed.

  14. Formation and in vitro biocompatibility of biomimetic hydroxyapatite coatings on chemically treated carbon substrates.

    PubMed

    Hoppe, Alexander; Will, Julia; Detsch, Rainer; Boccaccini, Aldo R; Greil, Peter

    2014-01-01

    Carbon derived materials such as pyrolytic carbon or carbon-carbon composites (CCCs) exhibit excellent mechanical properties making them promising candidates for bone replacement. However, these materials are considered bioinert and not to induce bone formation in vivo. In this study, a two-step chemical surface treatment including etching with HCl/HNO3 solution and subsequent soaking in CaCl2 solution was applied to carbon substrates in order to activate the materials surface towards bioactive behavior. The bioactivity was proven by soaking the samples in simulated body fluid (SBF) and formation of carbonated hydroxyapatite layer (HCA), which indicates the ability of the material to bond to bone in vivo. The materials surface is shown to be functionalized through the chemical etching creating COO(-)Ca(2+) complexes on the surface as confirmed by FTIR and XPS analyses. These ionic complexes provide nucleation sites for HAp precipitation. After similar immersion time in SBF under the condition of local supersaturation the thickness and homogeneity of the HAp layer were found to depend on the chemical pretreatment with HCl/HNO3. Homogenous HAp layers with a thickness ranging from ∼ 6 to ∼ 17 μm were achieved. The proposed bioactivating treatment of carbon stimulates HAp formation in vivo and can be considered an easy biomimetic approach for coating carbon derived materials with bone-like hydroxyapatite. In vitro cell assay with osteosarcoma cells (MG-63) showed increased cell viability (+70%) on HAp coated carbon substrates as compared to uncoated reference while both materials induced ALP expression in MG-63 cells confirming the osteoblastic phenotype.

  15. In vitro assessment of the biological response of Ti6Al4V implants coated with hydroxyapatite microdomains.

    PubMed

    Clavell, R Salvador; de Llano, J J Martín; Carda, C; Ribelles, J L Gómez; Vallés-Lluch, A

    2016-11-01

    Dental implantology is still an expanding field of scientific study because of the number of people that receive dental therapies throughout their lives worldwide. Recovery times associated to dental surgery are still long and demand strategies to improve integration of metallic devices with hard tissues. In this work, an in vitro ceramic coating is proposed to improve and accelerate osseointegration of titanium surfaces conceived to be used as dental implants or hip or knee prosthesis, shaped either as dishes or screws. Such coating consists of hydroxyapatite microdomains on the implant surfaces obtained in vitro by immersion of titanium alloy samples (Ti6Al4V) in a simulated body fluid. This titanium alloy is highly used in implant dentistry and trauma surgery, among other fields. Once the immersion times under physiological conditions yielding to different ceramic topographies on this alloy were set, the acellular coating time of major interest so as to optimize its biological development was determined. For this purpose, dental pulp mesenchymal cells were cultured on titanium coated surfaces with different hydroxyapatite outline, and cell adhesion, proliferation and morphology were followed through histological techniques and scanning electron microscopy. It was found that 4 days of acellular hydroxyapatite coating led to a significant cell adhesion on the titanium alloys at an early stage (6 h). Cells tended although to detach from the surface of the coating over time, but those adhered on domains of intricated topography or hydroxyapatite cauliflowers proliferated on them, leading to isolated large cell clusters. © 2016 Wiley Periodicals, Inc. J Biomed Mater Res Part A: 104A: 2723-2729, 2016.

  16. The effect of heat treatment on the morphology of D-Gun sprayed hydroxyapatite coatings.

    PubMed

    Erkmen, Z E

    1999-01-01

    In this study, the morphology of the Hydroxyapatite (HA) coatings sprayed on Ti alloy samples by Detonation Gun Spray (D-Gun) and the effect of aging before and after heat treatment in physiological solution were observed. Cross-sectional porosity and percentages of amorphous and crystal phase were measured using optical, electron microscopy, and X-ray diffraction analysis. Differential Thermogravimetric Analysis (DTA) was performed to estimate the glass-crystalline phase transformation temperatures. Heat-treatment at 300, 500, 700, 800 and 1200 degrees C were carried out to confirm DTA results. As a final analysis, the aging effect using Ringer's solution for 1 week on heat-treated and non-heat-treated samples was measured. It was observed that, in D-Gun sprayed samples, the cross-sectional porosity stayed in the accepted 5% range as reported for other spraying techniques.(1-5) On the other hand, surface porosity measured using the water immersion method remained in the conventional porosity limit of 15% for non-heat-treated samples. Heat-treatment had a small influence on the porosity while the crystallinity increased considerably; in addition, aging had little effect on HA crystallinity for heat treated samples. This work showed that D-gun sprayed HA coatings had lower porosity and better integrity than other coatings, due to which we can expect better performance during in vivo applications.

  17. Calcium carbonate hybrid coating promotes the formation of biomimetic hydroxyapatite on titanium surfaces

    NASA Astrophysics Data System (ADS)

    Cruz, Marcos Antônio E.; Ruiz, Gilia C. M.; Faria, Amanda N.; Zancanela, Daniela C.; Pereira, Lourivaldo S.; Ciancaglini, Pietro; Ramos, Ana P.

    2016-05-01

    CaCO3 particles dispersed in liquid media have proven to be good inductors of hydroxyapatite (HAp) growth. However, the use of CaCO3 deposited as thin films for this propose is unknown. Here, we report the growth of CaCO3 continuous films on Langmuir-Blodgett (LB) modified titanium surfaces and its use as HAp growth inductor. The Ti surfaces were modified with two, four, and six layers of dihexadecylphosphate (DHP)-LB films containing Ca2+, exposed to CO2 (g) for 12 h. The modified surfaces were immersed in simulated body fluid (SBF) at 37 °C for 36 h and submitted to bioactivity studies. This procedure originates bioactive coatings composed by non-stoichiometric HAp as evidenced by Fourier-Transform Infrared Spectroscopy (FTIR), X-ray Diffraction (XRD), and X-ray Photoelectron Spectroscopy (XPS). The presence of the CaCO3 film as pre-coating diminished the time necessary to growth continuous and homogeneous HAp films using a biomimetic approach. The surface properties of the films regarding their roughness, composition, charge, wettability, and surface free energy (γs) were accessed. The presence of HAp increased the wettability and γs of the surfaces. The coatings are not toxic for osteoblasts as observed for cell viability assays obtained after 7 and 14 days of culture. Moreover, the CaCO3 thin films promote the recovery of the osteoblasts viability more than the Ti surfaces themselves.

  18. Reduced graphene oxide-coated hydroxyapatite composites stimulate spontaneous osteogenic differentiation of human mesenchymal stem cells.

    PubMed

    Lee, Jong Ho; Shin, Yong Cheol; Jin, Oh Seong; Kang, Seok Hee; Hwang, Yu-Shik; Park, Jong-Chul; Hong, Suck Won; Han, Dong-Wook

    2015-07-21

    Human mesenchymal stem cells (hMSCs) have great potential as cell sources for bone tissue engineering and regeneration, but the control and induction of their specific differentiation into bone cells remain challenging. Graphene-based nanomaterials are considered attractive candidates for biomedical applications such as scaffolds in tissue engineering, substrates for SC differentiation and components of implantable devices, due to their biocompatible and bioactive properties. Despite the potential biomedical applications of graphene and its derivatives, only limited information is available regarding their osteogenic activity. This study concentrates upon the effects of reduced graphene oxide (rGO)-coated hydroxyapatite (HAp) composites on osteogenic differentiation of hMSCs. The average particle sizes of HAp and rGO were 1270 ± 4