Production of thin calcium phosphate coatings from glass source materials.

Calcium phosphate (CaP) coatings, from 40,000 to 200,000 nm thick, on titanium and titanium alloy substrates, were produced using radio frequency (RF) sputtering. Such coatings on dental implants have the potential for improving initial bone ingrowth rates. The success of these coatings may allow the movement from two stage implant systems to single stage implant systems, significantly reducing the time required for healing and fixture placement. Glass source materials were developed for the RF sputtering facility and the resultant coatings were characterized and compared to coatings sputtered from a conventional plasma sprayed hydroxyapatite (HA) source material. The coatings were characterized according to their chemistry, crystalline orientation, and residual strain.

Influence of coating strain on calcium phosphate thin-film dissolution.

The success of calcium phosphate (CaP) coatings used to accelerate initial bone growth onto dental implants can vary depending on the CaP phases present in the coating. In this study, the effect of CaP coating crystal structure and morphology on dissolution rates was investigated. RF magnetron-sputtered CaP coatings (NTC) were compared to a less strained coating (HTC) obtained from heat treatment of sputtered samples at 550 degrees C. Coating strain differences were apparent in XRD spectra where hydroxyapatite-like planes shifted by 0.5 degrees 2theta and 0.05 degrees 2theta for the NTC and HTC coatings, respectively. HTC XRD peak widths were broader than NTC peak widths, indicating smaller crystals or grain sizes. These differences in grain size were corroborated by imaging with scanning probe microscopy. NTC coatings dissolved at a 300% faster rate than HTC coatings. A major factor contributing to this kinetic effect was the level of strain in both coatings. These results suggest an alternate design for CaP coatings can be obtained through the manipulation of coating strain. Using this approach, delivery of different ionic gradients from CaP coatings to surrounding tissue environments can be obtained from surfaces having similar chemistries.

Analytical and mechanical testing of high velocity oxy-fuel thermal sprayed and plasma sprayed calcium phosphate coatings.

Plasma spraying (PS) is the most frequently used coating technique for implants; however, in other industries a cheaper, more efficient process, high-velocity oxy-fuel thermal spraying (HVOF), is in use. This process provides higher purity, denser, more adherent coatings than plasma spraying. The primary objective of this work was to determine if the use of HVOF could improve the mechanical properties of calcium phosphate coatings. Previous studies have shown that HVOF calcium phosphate coatings are more crystalline than plasma sprayed coatings. In addition, because the coatings are exposed to more complex loading profiles in vivo than standard ASTM tensile tests provide, a secondary objective of this study was to determine the applicability of four-point bend testing for these coatings. Coatings produced by HVOF and PS were analyzed by profilometry, diffuse reflectance Fourier transform infrared spectroscopy, X-ray diffraction, four-point bend, and ASTM C633 tensile testing. HVOF coatings were found to have lower amorphous calcium phosphate content, higher roughness values, and lower ASTM C633 bond strengths than PS coatings; however, both coatings had similar crystal unit cell sizes, phases present (including hydroxyapatite, beta-tricalcium phosphate, and tetracalcium phosphate), and four-point bend bond strengths. Thus, the chemical, structural, and mechanical results of this study, in general, indicate that the use of HVOF to produce calcium phosphate coatings is equivalent to those produced by plasma spraying.

Characterization of high velocity oxy-fuel combustion sprayed hydroxyapatite.

Bioceramic coatings, created by the high velocity oxy-fuel combustion spraying of hydroxyapatite (HA) powders onto commercially pure titanium, were characterized in order to determine whether this relatively new coating process can be successfully applied to bioceramic coatings of orthopaedic and dental implants. Fourier transform infrared spectroscopy, X-ray diffraction and scanning electron microscopy were used to characterize both the HA starting powders and coatings. A 12 wk immersion test was conducted and the resulting changes in the coatings were also characterized. Calcium ion release during dissolution was measured with flame atomic absorption during the first 6 weeks of the immersion study. A comparison of powder and coating X-ray diffraction patterns and lattice parameters revealed an HA-type coating with some loss in crystallinity. Fourier transform infrared results showed a partial loss of the OH- group during spraying, however the phosphate groups were still present. Scanning electron microscopy analysis showed a lamellar structure with very close coating-to-substrate apposition. The coatings experienced a loss of calcium during the immersion study, with the greatest release in calcium occurring during the first 6 days of the study. No significant structural or chemical changes were observed during the 12 wk immersion study. These results indicate that the high velocity oxy-fuel process can produce an HA-type coating; however, the process needs further optimization, specifically in the areas of coating-to-substrate bond strength and minimization of phases present other than HA, before it would be recommended for commercial use.