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The Influence of Spray Parameters on the Characteristics of Hydroxyapatite In-Flight Particles, Splats and Coatings by Micro-plasma Spraying

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Abstract

Hydroxyapatite (HA) is one of the most important bioceramic materials used in medical implants. The structure of HA coatings is closely related to their manufacturing process. In the present study, HA coatings were deposited on Ti-6Al-4V substrate by micro-plasma spraying. Results show that three distinct HA coatings could be obtained by changing the spraying power from 0.5 to 1.0 kW and spraying stand-off distance from 60 to 110 mm: (1) high crystallinity (93.3%) coatings with porous structure, (2) high crystallinity coatings (86%) with columnar structure, (3) higher amorphous calcium phosphate (ACP, 50%) coatings with dense structure. The in-flight particles melting state and splat topography was analyzed to better understand the formation mechanism of three distinct HA coatings. Results show that HA coatings sprayed at low spraying power and short stand-off distance exhibit high crystallinity and porosity is attributed to the presence of partially melted particles. High crystallinity HA coatings with (002) crystallographic texture could be deposited due to the complete melting of the in-flight particles and low cooling rate of the disk shape splats under higher spraying power and shorter SOD. However, splashed shape splats with relative high cooling can be provided by increasing SOD, which leads to the formation of ACP.

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Acknowledgments

The authors gratefully acknowledge the financial supports of the National Natural Science Foundation of China (51471010).

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Authors and Affiliations

  1. College of Materials Science and Engineering, Beijing University of Technology, Beijing, China

    Xiao-mei Liu, Ding-yong He, Yi-ming Wang, Zheng Zhou & Zhen Tan

  2. Beijing Engineering Research Center of Eco-Materials and LCA (Beijing University of Technology), Beijing, China

    Ding-yong He, Zheng Zhou, Guo-hong Wang & Zeng-jie Wang

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  1. Xiao-mei Liu
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Correspondence to Xiao-mei Liu or Ding-yong He.

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Liu, Xm., He, Dy., Wang, Ym. et al. The Influence of Spray Parameters on the Characteristics of Hydroxyapatite In-Flight Particles, Splats and Coatings by Micro-plasma Spraying. J Therm Spray Tech 27, 667–679 (2018). https://doi.org/10.1007/s11666-018-0698-y

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