Amorphous phase formation in plasma-sprayed hydroxyapatite coatings

Osteoblast Attachment on Bioactive Glass Air Particle Abrasion-Induced Calcium Phosphate Coating

Air particle abrasion (APA) using bioactive glass (BG) effectively decontaminates titanium (Ti) surface biofilms and the retained glass particles on the abraded surfaces impart potent antibacterial properties against various clinically significant pathogens. The objective of this study was to investigate the effect of BG APA and simulated body fluid (SBF) immersion of sandblasted and acid-etched (SA) Ti surfaces on osteoblast cell viability. Another goal was to study the antibacterial effect against Streptococcus mutans. Square-shaped 10 mm diameter Ti substrates (n = 136) were SA by grit blasting with aluminum oxide particles, then acid-etching in an HCl-H2SO4 mixture. The SA substrates (n = 68) were used as non-coated controls (NC-SA). The test group (n = 68) was further subjected to APA using experimental zinc-containing BG (Zn4) and then mineralized in SBF for 14 d (Zn4-CaP). Surface roughness, contact angle, and surface free energy (SFE) were calculated on test and control surfaces. In addition, the topography and chemistry of substrate surfaces were also characterized. Osteoblastic cell viability and focal adhesion were also evaluated and compared to glass slides as an additional control. The antibacterial effect of Zn4-CaP was also assessed against S. mutans. After immersion in SBF, a mineralized zinc-containing Ca-P coating was formed on the SA substrates. The Zn4-CaP coating resulted in a significantly lower Ra surface roughness value (2.565 μm; p < 0.001), higher wettability (13.35°; p < 0.001), and higher total SFE (71.13; p < 0.001) compared to 3.695 μm, 77.19° and 40.43 for the NC-SA, respectively. APA using Zn4 can produce a zinc-containing calcium phosphate coating that demonstrates osteoblast cell viability and focal adhesion comparable to that on NC-SA or glass slides. Nevertheless, the coating had no antibacterial effect against S. mutans.

Antibacterial Longevity of a Novel Gallium Liquid Metal/Hydroxyapatite Composite Coating Fabricated by Plasma Spray

Hydroxyapatite (HAp)-coated metallic implants are known for their excellent bioactivity and osteoconductivity. However, infections associated with the microstructure of the HAp coatings may lead to implant failures as well as increased morbidity and mortality. This work addresses the concerns about infections by developing novel composite coatings of HAp and gallium liquid metal (GaLM) using atmospheric plasma spray (APS) as the coating technique. Five weight percent Ga was mixed into a commercially supplied HAp powder using an orbital shaker; then, the HAp-Ga particle feedstock was coated onto Ti₆Al₄V substrates using the APS technique. The X-ray diffraction results indicated that Ga did not form any Ga-related phases in either the HAp-Ga powder or the respective coating. The GaLM filled the pores of the HAp coating presented both on the top surface and within the coating, especially at voids and cracks, to prevent failures of the coating at these locations. The wettability of the surface was changed from hydrophobic for the HAp coating to hydrophilic for the HAp-Ga composite coating. Finally, the HAp-Ga coating presented excellent antibacterial efficacies against both initial attachments and established biofilms generated from methicillin-resistant Staphylococcus aureus and Pseudomonas aeruginosa after 18 h and 7 days of incubation in comparison to the control HAp coating. This study shows that GaLM improves the antibacterial properties of HAp-based coatings without sacrificing the beneficial properties of conventional HAp coatings. Thus, the HAp-Ga APS coating is a viable candidate for antibacterial coatings.

Synthetic amorphous calcium phosphates (ACPs): preparation, structure, properties, and biomedical applications

Amorphous calcium phosphates (ACPs) represent a metastable amorphous state of other calcium orthophosphates (abbreviated as CaPO₄) possessing variable compositional but rather identical glass-like physical properties, in which there are neither translational nor orientational long-range orders of the atomic positions. In nature, ACPs of a biological origin are found in the calcified tissues of mammals, some parts of primitive organisms, as well as in the mammalian milk. Manmade ACPs can be synthesized in a laboratory by various methods including wet-chemical precipitation, in which they are the first solid phases, precipitated after a rapid mixing of aqueous solutions containing dissolved ions of Ca²⁺ and PO₄^3- in sufficient amounts. Due to the amorphous nature, all types of synthetic ACPs appear to be thermodynamically unstable and, unless stored in dry conditions or doped by stabilizers, they tend to transform spontaneously to crystalline CaPO₄, mainly to ones with an apatitic structure. This intrinsic metastability of the ACPs is of a great biological relevance. In particular, the initiating role that metastable ACPs play in matrix vesicle biomineralization raises their importance from a mere laboratory curiosity to that of a reasonable key intermediate in skeletal calcifications. In addition, synthetic ACPs appear to be very promising biomaterials both for manufacturing artificial bone grafts and for dental applications. In this review, the current knowledge on the occurrence, structural design, chemical composition, preparation, properties, and biomedical applications of the synthetic ACPs have been summarized.

Effects of composition of hydroxyapatite/gray titania coating fabricated by suspension plasma spraying on mechanical and antibacterial properties

While several metallic implants with bioactive coatings have been developed thus far for treating bone deformations or deterioration, a multifunctional coating with the desired mechanical and antibacterial properties has not been demonstrated. This study aimed to reveal the effect of the composition of hydroxyapatite (HAp)/gray titania coatings on the mechanical and antibacterial properties for biomedical applications. Suspension plasma spray (SPS) aided successful deposition of HAp/gray titania coatings on the surface of titanium substrates. The microstructure of coatings with different compositions was then characterized using scanning electron microscopy, X-ray diffraction, and Raman spectroscopy to identify the crystal structure. All results consistently demonstrated that SPS could transform Ti₂O₃ into TiO₂ with mixed Magneli phases, such as Ti₄O₇ and Ti₃O₅, which could typically demonstrate photocatalytic activity. Hardness, Young's modulus, and interfacial strength of composite coatings commonly increased with an increase in the weight percentage of TiO₂. A multi-modal damage assessment combining acoustic emission (AE), infrared ray camera (IR), and digital-image-correlation (DIC) was performed to monitor the damage process of HAp composite coating, which successfully revealed initiations of microcracks and nonlinear deformation at interface until fracture. Antibacterial test performed for examining the cytotoxic effects against E. coli under LED light irradiation conditions revealed that SPS HAp/gray titania coating could significantly enhance the antibacterial properties. Enhanced antibacterial properties can be attributed to an increase in the number of Magneli phases and better bacterial adhesion was attributed to hydrophilic properties conferred by submicron-sized particles. Hence, SPS can help fabricate visible light-responsive antibacterial coating, which can be used for medical devices.

Osseointegrating and phase-oriented micro-arc-oxidized titanium dioxide bone implants

Here, we present a bone implant system of phase-oriented titanium dioxide (TiO₂) fabricated by the micro-arc oxidation method (MAO) on β-Ti to facilitate improved osseointegration. This (101) rutile-phase-dominant MAO TiO₂ (R-TiO₂) is biocompatible due to its high surface roughness, bone-mimetic structure, and preferential crystalline orientation. Furthermore, (101) R-TiO₂ possesses active and abundant hydroxyl groups that play a significant role in enhancing hydroxyapatite formation and cell adhesion and promote cell activity leading to osseointegration. The implants had been elicited their favorable cellular behavior in vitro in the previous publications; in addition, they exhibit excellent shear strength and promote bone-implant contact, osteogenesis, and tissue formation in vivo. Hence, it can be concluded that this MAO R-TiO₂ bone implant system provides a favorable active surface for efficient osseointegration and is suitable for clinical applications.

Structural and Chemical Hierarchy in Hydroxyapatite Coatings

Hydroxyapatite coatings need similarly shaped splats as building blocks and then a homogeneous microstructure to unravel the structural and chemical hierarchy for more refined improvements to implant surfaces. Coatings were thermally sprayed with differently sized powders (20–40, 40–63 and 63–80 µm) to produce flattened homogeneous splats. The surface was characterized for splat shape by profilometry and Atomic force microscopy (AFM), crystal size by AFM, crystal orientation by X-ray diffraction (XRD) and structural variations by XRD. Chemical composition was assessed by phase analysis, but variations in chemistry were detected by XRD and Raman spectroscopy. The resulting surface electrical potential was measured by Kelvin probe AFM. Five levels of structural hierarchy were suggested: the coating, the splat, oriented crystals, alternate layers of oxyapatite and hydroxyapatite (HAp) and the suggested anion orientation. Chemical hierarchy was present over a lower range of order for smaller splats. Coatings made from smaller splats exhibited a greater electrical potential, inferred to arise from oxyapatite, and supplemented by ordered OH⁻ ions in a rehydroxylated surface layer. A model has been proposed to show the influence of structural hierarchy on the electrical surface potential. Structural hierarchy is proposed as a means to further refine the properties of implant surfaces.

Mechanical Properties of Strontium–Hardystonite–Gahnite Coating Formed by Atmospheric Plasma Spray

In this work, we measured the mechanical properties and tested the cell viability of a bioceramic coating, strontium–hardystonite–gahnite (Sr–HT–G, Sr–Ca2ZnSi2O7–ZnAl2O4), to evaluate potential use of this novel bioceramic for bone regeneration applications. The evaluation of Sr–HT–G coatings deposited via atmospheric plasma spray (APS) onto Ti–6Al–4V substrates have been contrasted to the properties of the well-known commercial standard coating of hydroxyapatite (HAp: Ca10(PO4)6(OH)2). The Sr–HT–G coating exhibited uniform distribution of hardness and elastic moduli across its cross-section; whereas the HAp coating presented large statistical variations of these distributions. The Sr–HT–G coating also revealed higher results of microhardness, nanohardness and elastic moduli than those shown for the HAp coating. The nanoscratch tests for the Sr–HT–G coating presented a low volume of material removal without high plastic deformation, while the HAp coating revealed ploughing behaviour with a large pileup of materials and plastic deformation along the scratch direction. Furthermore, nanoscanning wear tests indicated that Sr–HT–G had a lower wear volume than the HAp coating. The Sr–HT–G coating had slightly higher cell attachment density and spreading area compared to the HAp coating indicating that both coatings have good biocompatibility for bone marrow mesenchymal stem cells (BMSCs).

In-vitro comparison of hydroxyapatite coatings obtained by cold spray and conventional thermal spray technologies

Hydroxyapatite (HA) coatings onto Ti6Al4V alloy substrates were obtained by several thermal spray technologies: atmospheric plasma spray (APS) and high velocity oxy fuel (HVOF), together with the cold spray (CS) technique. A characterization study has been performed by means of surface and microstructure analyses, as well as biological performance. In-vitro tests were performed with primary human osteoblasts at 1, 7 and 14 days of cell culture on substrates. Cell viability was tested by MTS and LIVE/DEAD assays, cell differentiation by alkaline phosphatase (ALP) quantification, and cell morphology was analyzed by scanning electron microscopy. The HA coatings showed an increase of HA crystallinity from 62,4% to 89%, but also an increase of hydrophilicity from ∼32° to 0°, with the decrease of the operating temperature of the thermal spray techniques (APS > HVOF > CS). Additionally, APS HA coatings showed more surface micro-features than HVOF and CS HA coatings; cells onto APS HA coatings showed faster attachment by acquiring osteoblastic morphology in comparison with the rounded cell morphology observed onto CS HA coatings at 1 day of cell culture. HVOF HA coatings also showed proper cell adherence but did not show extended filopodia as cells onto APS HA coatings. However, at 14 days of cell culture, higher cell proliferation and differentiation was detected on HA coatings with higher crystallinity (HVOF and CS techniques). Cell attachment is suggested to be favoured by surface micro-features but also moderate surface wettability whereas cell proliferation and differentiation is suggested to be highly influenced by HA crystallinity and crystal size.

X-ray diffraction analysis of hydroxyapatite-coated in different plasma gas atmosphere on Ti and Ti-6Al-4V

Objective:

The aim is to study the effect of plasma working gas on composition, crystallinity, and microstructure of hydroxyapatite (HA) coated on Ti and Ti-6Al-4V metal substrates.

Materials and Methods:

Ti and Ti-6Al-4V metal substrates were coated with HA by plasma spray using four plasma gas atmospheres of argon, argon/hydrogen, nitrogen, and nitrogen/hydrogen. The degree of crystallinity, the phases present, and microstructure of HA coating were characterized using X-ray diffraction and scanning electron microscopy.

Results:

Variation in crystallinity and the microstructure of HA coating on plasma gas atmosphere was observed. Micro-cracks due to thermal stresses and shift in the 2θ angle of HA compared to feedstock was seen.

Conclusion:

Plasma gas atmosphere has a significant influence on composition, crystallinity, and micro-cracks of HA-coated dental implants.

Enhancement of osteoblast activity on nanostructured NiTi/hydroxyapatite coatings on additive manufactured NiTi metal implants by nanosecond pulsed laser sintering

Background

The osteoinductive behaviors of nitinol (NiTi)-based metal implants for bone regeneration are largely dependent on their surface composition and topology. Continuous-mode laser sintering often results in complete melting of the materials and aggregation of particles, which lack control of heat transfer, as well as microstructural changes during sintering of the nanocomposite materials.

Methods

In the current study, in situ direct laser deposition was used to additively manufacture three-dimensional NiTi structures from Ni and Ti powders. The mechanical property of NiTi has been shown to be similar to bone. Nanosecond pulsed laser sintering process was then utilized to generate a nanoporous composite surface with NiTi alloy and hydroxyapatite (HA) by ultrafast laser heating and cooling of Ni, Ti, and HA nanoparticles mixtures precoated on the 3D NiTi substrates; HA was added in order to improve the biocompatibility of the alloy. We then studied the underlying mechanism in the formation of NiTi/HA nanocomposite, and the synergistic effect of the sintered HA component and the nanoporous topology of the composite coating. In addition, we examined the activity of bone-forming osteoblasts on the NiTi/HA surfaces. For this, osteoblast cell morphology and various biomarkers were examined to evaluate cellular activity and function.

Results

We found that the nanoscale porosity delivered by nanosecond pulsed laser sintering and the HA component positively contributed to osteoblast differentiation, as indicated by an increase in the expression of collagen and alkaline phosphatase, both of which are necessary for osteoblast mineralization. In addition, we observed topological complexities which appeared to boost the activity of osteoblasts, including an increase in actin cytoskeletal structures and adhesion structures.

Conclusion

These findings demonstrate that the pulsed laser sintering method is an effective tool to generate biocompatible coatings in complex alloy-composite material systems with desired composition and topology. Our findings also provide a better understanding of the osteoinductive behavior of the sintered nanocomposite coatings for use in orthopedic and bone regeneration applications.

Characteristics of (002) Oriented Hydroxyapatite Coatings Deposited by Atmospheric Plasma Spraying

Hydroxyapatite (HA) coatings with strong (002) preferred orientation were successfully prepared on Ti-6Al-4V substrates with conventional atmospheric plasma spraying (APS). The intensity changes of (002) preferred orientation along the coating depth were investigated and the mechanical properties of these coatings were analyzed. Results indicated that the intensity of (002) preferred orientation at a distance of longer than ~90 mm from the interface showed a high value, where uniformly distributed columnar grains in a direction perpendicular to the coating surface were observed. The results obtained from experiments on the mechanical properties revealed that the (002) oriented coatings prepared by conventional APS technique exhibited excellent mechanical properties. Meanwhile, this study provided a simple and rapid method for the preparation of HA coatings with (002) preferred orientation.

Adhesion and mechanical properties of nanocrystalline hydroxyapatite coating obtained by conversion of atomic layer-deposited calcium carbonate on titanium substrate

The purpose of this study was to evaluate the mechanical properties of nanocrystalline hydroxyapatite coating by tensile adhesion testing and scratch testing. The coating was manufactured on titanium substrate by converting atomic layer-deposited (ALD) calcium carbonate thin film in dilute phosphate solution. The tensile adhesion testing was performed with hydraulic testing device in accordance with ISO 4624 and ISO 16276-1. Scratch testing was done according to SFS-EN 13523-12 with spherical 10 µm scratching tip. Characterization of the samples was done with light and electron microscopy after which they were stained with alizarin red and the failure modes and loadings were analyzed. The highest obtained tensile adhesion value was 6.71 MPa produced with 4000 ALD cycles, converted to hydroxyapatite in alkaline solution, and annealed for 30 min in 700 °C. The annealing improved the adhesion values by approximately 0.8 MPa, but examining the samples with electron microscopy showed intact coating in both annealed and non-annealed samples. Samples produced with 4000 cycles performed better in testing than 2000 cycle samples, and better adhesion was also achieved with alkaline conversion solution compared to neutral solution.

Functionalized coatings by cold spray: An in vitro study of micro- and nanocrystalline hydroxyapatite compared to porous titanium

Three different surface treatments on a Ti6Al4V alloy have been in vitro tested for possible application in cementless joint prosthesis. All of them involve the novelty of using the Cold Spray technology for their deposition: (i) an as-sprayed highly rough titanium and, followed by the deposition of a thin hydroxyapatite layer with (ii) microcrystalline or (iii) nanocrystalline structure. Primary human osteoblasts were extracted from knee and seeded onto the three different surfaces. Cell viability was tested by MTS and LIVE/DEAD assays, cell differentiation by alkaline phosphatase (ALP) quantification and cell morphology by Phalloidin staining. All tests were carried out at 1, 7 and 14 days of cell culture. Different cell morphologies between titanium and hydroxyapatite surfaces were exhibited. At 1 day of cell culture, cells on the titanium coating were spread and flattened, expanding the filopodia actin filaments in all directions, while cells on the hydroxyapatite coatings showed round like-shape morphology due to slower attachment. Higher cell viability was detected at all times of cell culture on titanium coating due to a better attachment at 1 day. However, from 7 days of cell culture, cells on hydroxyapatite showed good attachment onto surfaces and highly increased their proliferation, mostly on nanocrystalline, achieving similar cell viability levels than titanium coatings. ALP levels were significantly higher in titanium, in part, because of greatest cell number. Overall, the best cell functional results were obtained on titanium coatings whereas microcrystalline hydroxyapatite presented the worst cellular parameters. However, results indicate that nanocrystalline hydroxyapatite coatings may achieve promising results for the faster cell proliferation once cells are attached on the surface.

Biomimetic Mineralization of Biomaterials Using Simulated Body Fluids for Bone Tissue Engineering and Regenerative Medicine<sup/>

Development of synthetic biomaterials imbued with inorganic and organic characteristics of natural bone that are capable of promoting effective bone tissue regeneration is an ongoing goal of regenerative medicine. Calcium phosphate (CaP) has been predominantly utilized to mimic the inorganic components of bone, such as calcium hydroxyapatite, due to its intrinsic bioactivity and osteoconductivity. CaP-based materials can be further engineered to promote osteoinductivity through the incorporation of osteogenic biomolecules. In this study, we briefly describe the microstructure and the process of natural bone mineralization and introduce various methods for coating CaP onto biomaterial surfaces. In particular, we summarize the advantages and current progress of biomimetic surface-mineralizing processes using simulated body fluids for coating bone-like carbonated apatite onto various material surfaces such as metals, ceramics, and polymers. The osteoinductive effects of integrating biomolecules such as proteins, growth factors, and genes into the mineral coatings are also discussed.

In vitro evaluation of hydroxyapatite coatings with (002) crystallographic texture deposited by micro-plasma spraying

Hydroxyapatite (HA) coatings are usually deposited on the metallic implant to increase the biocompatibility and protect the bloodstream from harmful metal ions. Atmospheric plasma spray (APS) is known as a cost effective deposition method. However, the low crystallinity of APS deposited coating accelerates its dissolution in body fluid. We used micro-plasma spray (MPS) to develop chemically stable HA coatings, and performed APS as reference. Results showed that MPS deposited coatings exhibited (002) crystallographic texture while the reference sample did not. The texture intensity and crystallinity were improved by shortening stand-off distance. These suggested that different formation procedures of HA coatings were involved and three mechanisms were proposed by sketching typical splats. To evaluate the chemical stability of the coatings in a physiological environment, in vitro experiments were performed in Hanks' solution. Well crystallized (~100%) HA coating with the strongest crystallographic texture exhibited superior stability up to 14days. Crystals with (002) orientation was more stable than that with (211) orientation. Hence columnar structure with nanopores emerged on the coating surface after incubation, and this may facilitate the future osteoblast growth. Furthermore, HA coating with weak and no crystallographic texture induced apatite layer. However, vertical cracks and cleavage at coating-apatite interface may cause coating separation.

Effect of Roughness on in Situ Biomineralized CaP-Collagen Coating on the Osteogenesis of Mesenchymal Stem Cells

Because of its outstanding osteo-conductive property, a calcium phosphate (CaP) coating has been used as an implant coating for bone tissue engineering. Nevertheless, the issues, such as harsh fabrication conditions, long-term stability and biocompatibility, and the requirement for expensive instruments, still exist in current coating techniques. To address these issues, the CaP coatings doped with collagen (CaP-Col) were in situ generated on polyelectrolyte multilayers (PEMs) by incubating PEMs in a mixture of the collagen, phosphate, and calcium ions. The resulting coatings have controllable physical properties (chemical composition, crystallinity, and roughness) and good stability before and after incubation with cell culture medium. We also found that both the cellular viability and osteogenesis of mesenchymal stem cells (MSCs) were closely related to the roughness of PEMs/CaP-Col, one of the easily ignored physical factors in current coating designs but very critical. The existed roughness window (between 18 ± 1.2 and 187 ± 7.3 nm) suitable for MSC proliferation on PEMs/CaP-Col coating and the optimal roughness (∼98 ± 3.5 nm) for MSC osteogenesis further demonstrated that the roughness was a critical factor for bone formation. Therefore, we envision that our exploration of the effects of surface roughness on MSC behaviors would provide better guidance for the future design of material coating and eventual medical success.

Calcium orthophosphate deposits: Preparation, properties and biomedical applications

Since various interactions among cells, surrounding tissues and implanted biomaterials always occur at their interfaces, the surface properties of potential implants appear to be of paramount importance for the clinical success. In view of the fact that a limited amount of materials appear to be tolerated by living organisms, a special discipline called surface engineering was developed to initiate the desirable changes to the exterior properties of various materials but still maintaining their useful bulk performances. In 1975, this approach resulted in the introduction of a special class of artificial bone grafts, composed of various mechanically stable (consequently, suitable for load bearing applications) implantable biomaterials and/or bio-devices covered by calcium orthophosphates (CaPO4) to both improve biocompatibility and provide an adequate bonding to the adjacent bones. Over 5000 publications on this topic were published since then. Therefore, a thorough analysis of the available literature has been performed and about 50 (this number is doubled, if all possible modifications are counted) deposition techniques of CaPO4 have been revealed, systematized and described. These CaPO4 deposits (coatings, films and layers) used to improve the surface properties of various types of artificial implants are the topic of this review.

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

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.

Characterization of Thermal Sprayed Hydroxyapatite Coatings on Some Biomedical Implant Materials

Purpose

To characterize two thermal sprayed coatings of different particle-sized hydroxyapatite on some biomedical implant materials.

Methods

Characterization of the as-sprayed coatings was performed using x-ray diffractometer, scanning electron microscopy/energy dispersive spectroscopy, and x-ray mapping techniques. Bond strength of the sprayed coatings measured as per ASTM-C633 standard and cell culture studies were performed to assess the biocompatibility of the coatings.

Results

The results indicated that, HA coatings of 10 μm particle sized powder were completely amorphous, while that of 30 μm sized powder consisted of crystalline HA with minor tetracalcium phosphate and tricalcium phosphate phases. This flame spray HA-A and HA-B coatings exhibited higher bond strength (67.8 and 49.3 MPa respectively) in comparison with other thermal spray HA coating techniques reported in literature. In vitro biocompatibility studies revealed that HA-B coated specimens had good biocompatibility with a human osteosarcoma cell line KHOSNP (R-970-5).

Conclusions

These observations show that particle size of HA powders have a significant effect on the phase composition, microstructure, roughness and biocompatibility of deposited coatings. HA-B coatings were found to be metallurgically better than the HA-A coating from the point of view of biomedical applications.

Preparation and characterization of bioactive composites and fibers for dental applications

OBJECTIVES

The present study was carried out to create composites and fibers using polyurethane (PU) with hydroxyapatite (HA) that could be used for dental applications.

METHODS

Composites with varying HA concentration were prepared by solution casting technique. Similarly, PU-HA fibers with varying PU hard and soft segments and fixed HA concentration were also prepared. Various characterization techniques, such as, X-ray diffractometry, differential scanning calorimetry, scanning electron microscopy and Fourier transform infrared spectroscopy in conjunction with photo-acoustic sampling cell were employed to study the composites and fibers for changes in their physicochemical properties before and after immersion in artificial saliva at 37°C for up to 5 days.

RESULTS

The results indicated formation of amorphous apatite layers with maximum amorphicity in composites containing highest amount of HA with 5 days of immersion in artificial saliva. Similarly, fibers with more PU hard segment resulted in better transformation of crystalline HA to its amorphous state with increasing immersion time thus confirming the bioactive nature of the HA-PU fibers.

SIGNIFICANCE

Concentrations of HA and PU hard segment along with the duration of immersion in artificial saliva are two major factors involved in the modification of solid-state properties of HA. The amorphous apatite layer on the surface is known to have tendency to bind with living tissues and hence the use of optimum amount of HA and PU hard segment in composites and fibers, respectively could help in the development of novel dental filling material.

Optimal Conditions of Electrostatic Spray Deposition (ESD) for Composite Biomaterials Coating for Biomedical Applications

Various types of metals and alloys are used for medical implants due to their excellent mechanical properties and corrosion resistance; however, their lacks of osteoinductive properties bring about the introduction of biomaterials which can help enhancing the bioactivity between the bones and the implants. Hydroxyapatite (Ca10(PO4)6(OH)2, or HA) which is one of the calcium phosphates that has similar mineral constituents of human bone, has been used as coating material to the metals/alloys substrate. Coating HA usually involves high-temperature such as the plasma spraying coating, which can alter the crystal structure of the HA partially become amorphous. The amorphous nature of HA lessen the benefits of coating with the biomaterial HA. Electrostatic spray deposition (ESD) was used in this research due to the fact that this process is simple, economical, and room-temperature operated. The preliminary results showed a promising thickness layer of about 40 μm; however, the adhesion of the coated layer to the stainless steel 316L was improved by mixing the HA powder with phosphate bioglass and cured in the vacuum furnace at 700oC. Taguchi experimental design technique was used for screening several ESD process parameters: powder feed rate, voltage, current, air volume, distances, time, and nozzle types to significant factors to the coated thickness of the ESD process. The results showed that feed rate, air volume, and time were the significant factors and then Full factorial analysis and response surface method was used for obtaining optimal conditions for the coating, as well as the predicted equation for determine the thickness coated layer with significant factors.

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

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.

Calcium orthophosphate coatings, films and layers

In surgical disciplines, where bones have to be repaired, augmented or improved, bone substitutes are essential. Therefore, an interest has dramatically increased in application of synthetic bone grafts. As various interactions among cells, surrounding tissues and implanted biomaterials always occur at the interfaces, the surface properties of the implants are of the paramount importance in determining both the biological response to implants and the material response to the physiological conditions. Hence, a surface engineering is aimed to modify both the biomaterials, themselves, and biological responses through introducing desirable changes to the surface properties of the implants but still maintaining their bulk mechanical properties. To fulfill these requirements, a special class of artificial bone grafts has been introduced in 1976. It is composed of various mechanically stable (therefore, suitable for load bearing applications) biomaterials and/or bio-devices with calcium orthophosphate coatings, films and layers on their surfaces to both improve interactions with the surrounding tissues and provide an adequate bonding to bones. Many production techniques of calcium orthophosphate coatings, films and layers have been already invented and new promising techniques are continuously investigated. These specialized coatings, films and layers used to improve the surface properties of various types of artificial implants are the topic of this review.

Promotion of pro-osteogenic responses by a bioactive ceramic coating

The objective of this study was to analyze the responses of bone-forming osteoblasts to Ti-6Al-4V implant material coated with silica-calcium phosphate nanocomposite (SCPC50). Osteoblast differentiation at the interface with SCPC50-coated Ti-6Al-4V was correlated to the adsorption of high amount of serum proteins, high surface affinity to fibronectin, Ca uptake from and P and Si release into the medium. SCPC50-coated Ti-6Al-4V adsorbed significantly more serum protein (p < 0.05) than control uncoated substrates. Moreover, Western blot analysis showed that the SCPC50 coating had a high affinity for serum fibronectin. Protein conformation analyses by FTIR showed that the ratio of the area under the peak for amide I/amide II bands was significantly higher (p < 0.05) on the surface of SCPC50-coated substrates than that on the surface of the control uncoated substrates. Moreover, ICP - OES analyses indicated that SCPC50-coated substrates withdrew Ca ions from, and released P and Si ions into, the tissue culture medium, respectively. In conjunction with the favorable protein adsorption and modifications in medium composition, MC3T3-E1 osteoblast-like cells attached to SCPC50-coated substrates expressed 10-fold higher level of mRNA encoding osteocalcin and had significantly higher production of osteopontin and osteocalcin proteins than cells attached to the uncoated Ti-6A1-4V substrates. In addition, osteoblast-like cells attached to the SCPC50-coated substrates produced significantly lower levels of the inflammatory and osteoclastogenic cytokines, IL-6, IL-12p40, and RANKL than those attached to uncoated Ti-6Al-4V substrates. These results suggest that SCPC50 coating could enhance bone integration with orthopedic and maxillofacial implants while minimizing the induction of inflammatory bone cell responses.

Biphasic, triphasic and multiphasic calcium orthophosphates

Biphasic, triphasic and multiphasic (polyphasic) calcium orthophosphates have been sought as biomaterials for reconstruction of bone defects in maxillofacial, dental and orthopedic applications. In general, this concept is determined by advantageous balances of more stable (frequently hydroxyapatite) and more resorbable (typically tricalcium orthophosphates) phases of calcium orthophosphates, while the optimum ratios depend on the particular applications. Therefore, all currently known biphasic, triphasic and multiphasic formulations of calcium orthophosphate bioceramics are sparingly soluble in water and, thus, after being implanted they are gradually resorbed inside the body, releasing calcium and orthophosphate ions into the biological medium and, hence, seeding new bone formation. The available formulations have already demonstrated proven biocompatibility, osteoconductivity, safety and predictability in vitro, in vivo, as well as in clinical models. More recently, in vitro and in vivo studies have shown that some of them might possess osteoinductive properties. Hence, in the field of tissue engineering biphasic, triphasic and multiphasic calcium orthophosphates represent promising biomaterials to construct various scaffolds capable of carrying and/or modulating the behavior of cells. Furthermore, such scaffolds are also suitable for drug delivery applications. This review summarizes the available information on biphasic, triphasic and multiphasic calcium orthophosphates, including their biomedical applications. New formulations are also proposed.

Amorphous calcium phosphate offers improved crack resistance: a design feature from nature?

Amorphous calcium phosphate (ACP) is found in biological organisms and coated implants, used in calcium phosphate cements, and has been recently confirmed as a precursor in mineralized tissue; however, nothing is known about crack initiation in ACP or its fracture toughness. The objective of this study was to determine the crack resistance of ACP to help understand its role in biological organisms and assist in the design of calcium-phosphate-based implants. ACP was manufactured by quenching droplets to form a bulk sample and individual splats. Testing of Berkovich and cube-corner indenter types revealed that the Berkovich indenter was more suitable, providing ease of crack detection. Nanoindentation was performed on polished ACP and hydroxyapatite (HAp), and cracks were identified with scanning electron microscopy. Additional nanoindentation was done on splats to assess the suitability for testing microarrays used in high throughput discovery of new bioceramics. ACP required about three times more force to initiate a crack compared to sintered HAp, but about nine times more than a single crystal. Crack initiation resistance decreased with increasing grain size. The fracture toughness of ACP was comparable to a single crystal, but higher for nanograined HAp. The crack initiation load can be potentially used for evaluating microsized samples. ACP prevents crack formation, but requires the presence of nanograins to provide a greater toughness. The implications of the higher crack initiation load in ACP are discussed for biological organisms and thermally processed biomaterials such as thermally sprayed and sintered HAp.

Selection of the implant and coating materials for optimized performance by means of nanoindentation

Mechanical compatibility between a coating and a substrate is important for the longevity of implant materials. While previous studies have utilized the entire coating for analysis of mechanical compatibility of the surface, this study focuses on the nanoindentation of a uniformly thermally sprayed splat. Hydroxyapatite was thermally sprayed to create a homogeneous deposit density, as confirmed by microRaman spectroscopy, of amorphous calcium phosphate. Substrates were commercially pure Ti, Ti-6Al-4V, Co-Cr alloy and stainless steel. Nanoindentation revealed that splats deposited on the different metals have similar hardness and elastic modulus values of 4.2 ± 0.2 GPa and 80 ± 3 GPa, respectively. The mechanical properties were affected by the substrate type more than residual stresses, which were found to be low. It is recommended that amorphous calcium phosphate is annealed to relieve the quenching stress or that appropriate temperature histories are chosen to relax the stress created in cooling the coating assembly.

Induction Plasma Sprayed Nano Hydroxyapatite Coatings on Titanium for Orthopaedic and Dental Implants

This paper reports preparation of a highly crystalline nano hydroxyapatite (HA) coating on commercially pure titanium (Cp-Ti) using inductively coupled radio frequency (RF) plasma spray and their in vitro and in vivo biological response. HA coatings were prepared on Ti using normal and supersonic plasma nozzles at different plate powers and working distances. X-ray diffraction (XRD) and Fourier transformed infrared spectroscopic (FTIR) analysis show that the normal plasma nozzle lead to increased phase decomposition, high amorphous calcium phosphate (ACP) phase formation, and severe dehydroxylation of HA. In contrast, coatings prepared using supersonic nozzle retained the crystallinity and phase purity of HA due to relatively short exposure time of HA particles in the plasma. In addition, these coatings exhibited a microstructure that varied from porous and glassy structure at the coating-substrate interface to dense HA at the top surface. The microstructural analysis showed that the coating was made of multigrain HA particles of ~200 nm in size, which consisted of recrystallized HA grains in the size range of 15- 20 nm. Apart from the type of nozzle, working distance was also found to have a strong influence on the HA phase decomposition, while plate power had little influence. Depending on the plasma processing conditions, a coating thickness between 300 and 400 μm was achieved where the adhesive bond strengths were found to be between 4.8 MPa to 24 MPa. The cytotoxicity of HA coatings was examined by culturing human fetal osteoblast cells (hFOB) on coated surfaces. In vivo studies, using the cortical defect model in rat femur, evaluated the histological response of the HA coatings prepared with supersonic nozzle. After 2 weeks of implantation, osteoid formation was evident on the HA coated implant surface, which could indicate early implant- tissue integration in vivo.

Amorphous calcium phosphates: synthesis, properties and uses in biomaterials

This review paper on amorphous calcium phosphates (ACPs) provides an update on several aspects of these compounds which have led to many studies and some controversy since the 1970s, particularly because of the lack of irrefutable proof of the occurrence of an ACP phase in mineralised tissues of vertebrates. The various synthesis routes of ACPs with different compositions are reported and the techniques used to characterise this phase are reviewed. We focus on the various physico-chemical properties of ACPs, especially the reactivity in aqueous media, which have been exploited to prepare bioactive bone substitutes, particularly in the form of coatings and cements for orthopaedic applications and composites for dental applications.

Study of Adhesion Relationship of Hydroxyapatite-Titania Coating Obtained by HVOF

Hydroxyapatite (HA) coatings are widely used to improve the biocompatibility of titanium substrates. The main problem concerning these coatings is related with the bad adhesion characteristic of the ceramic/metal interface. A TiO2 interlayer can be used to improve the adhesion of the coating; however the TiO2 is a bioinert material. Then, a solution can be the use of a mixture of HA-TiO2 (60% wt HA- 40% wt TiO2) powder has been sprayed by using High Velocity Oxy-Fuel (DJH-2700) for different spraying distances. The adhesion of the coatings has been mechanically tested and the values have been compared with the values obtained for coatings that have been immersed in simulated body fluid solution (SBF) after 24 and 120 hours. The crystallinity degree of the HA plays an important role on it for the dissolution affecting the behaviour of the interface at the same time it is also important osteoclastic resorption and carbonate apatite precipitation.

Surface nanocrystallization of hydroxyapatite coating

Nanocharactered biomaterials, such as nanopowders, nanocrystalline compacts and nanostructured films, as well as materials with nanoscale roughness, have attracted much attention recently, due to their clear effects on cell response. Surface nanocrystallization of plasma-sprayed hydroxyapatite (HA) coating can be realized by conventional post-heat treatment. This study reveals that 20-30nm nanocrystals formed on HA coatings post-heat treated at 650 degrees C, and the increase in holding time increased the number of surface nanocrystals and intensified their aggregation. Hard aggregation occurred when HA coatings were repetitively post-heat treated. This indicates that the surface nanocrystallization is controllable. Cell experiments were carried out with rat calvarial osteoblasts. The post-heat treated HA coatings exhibit an obviously better osteoblast response than the as-sprayed coatings. Well-flattened cells attached themselves to the coating surfaces, with a good interaction between their filopodia and the nanocrystallized region. It is proposed that the surface nanocrystallization should be taken into account when the post-heat treatment process is introduced for the fabrication of HA coatings.

Influence of experimental parameters on spatial phase distribution in as-sprayed and incubated hydroxyapatite coatings

In the present study, the behavior and properties of plasma-sprayed hydroxyapatite coatings [Ca(10)(PO(4))(6)(OH)(2), HAp] were investigated in relation to the spraying process. The experiments were focused on the influence of type of feedstock and spray power on the phase composition and distribution within the coatings. Depth profiles of the coatings were investigated before and after incubation in revised simulated body fluid (SBF) by X-ray diffraction and infrared spectroscopy. Besides HAp, the coatings contain oxyapatite (OAp) and carbonate apatite (CAp). Additionally, tricalcium phosphate (TCP), tetracalcium phosphate (TTCP), CaO, and an amorphous phase were detected in the coatings. The HAp content directly depends on the used spray powder and spray power, where the influence of spray powder is much higher than the influence of the spray power. The grain size range of the spray powder strongly influences the HAp content in the coating and the formation of CaO. The in vitro behavior of the coatings in simulated body fluid mainly depends on the contents of CaO and amorphous calcium phosphate, respectively. The formation of portlandite due to the reaction of the coating with the SBF is strongly influenced by the porosity of the coatings and can be used as an indicator for the depth of interaction between fluid and coating.

In vitro dissolution of plasma-sprayed hydroxyapatite coatings with different characteristics: experimental study and modeling

The dissolution of plasma-sprayed hydroxyapatite (PHA) coatings with different characteristics, produced by various spraying conditions, in a Tris-buffered solution at pH 7.4 was experimentally studied through the measurement of the release of calcium ions. The phase composition of the coatings at surface and interface, and the porosity were evaluated. The analytical modeling revealed that the calcium dissolution process was composed of two stages. The first stage was found to be both surface and diffusion controlled. The second stage was an exactly diffusion-controlled dissolution. In the first stage, the rate of dissolution and the solubility of the coatings with minimum contents of impurity phases were mainly influenced by the contents of recrystallized HA (RHA) and amorphous calcium phosphate (ACP). It is suggested that the optimized values of the ACP and the RHA at the coating surface can tend to encourage the early fixation properties of the PHA coatings.

Influence of fluorapatite on the properties of thermally sprayed hydroxyapatite coatings

Thermally sprayed hydroxyapatite has been the widely used on orthopaedic prosthesis to induce bone growth and facilitate bone attachment. However, hydroxyapatite has a greater affinity for the formation of an amorphous phase in the thermally sprayed coating that results in the release of excessive amount of mineral ions from the implant coating leading to a saturated environment in the immediate vicinity of the bone cells. Fluorapatite however is highly crystalline and offers the potential for lower mineral ion release by dissolution. Thus study investigates the influence of fluorapatite in a thermally sprayed hydroxyapatite coating. Mechanical blends of fluorapatite with hydroxyapatite were thermally sprayed, characterized with X-ray diffraction, SEM, FTIR, optical microscopy for microstructure, roughness and tested for solubility. Cathodoluminescence microscopy was used to examine the resorbed coating surface. Fluorapatite coatings crystallized more readily and produce a greater coating roughness. The roughness in fluorapatite coatings arises from less flattened droplets that show a tendency for finger formation. Addition of fluorapatite increases coating crystallinity. The use of slower resorbing fluorapatite produces less particle release which favors improved osseointegration. Less change in the surface topography during resorption can be used to an advantage to control the coating surface presented to cells and extra cellular matrix proteins.

Significance of melt-fraction in HVOF sprayed hydroxyapatite particles, splats and coatings

Microstructure characterization and property evaluation of high velocity oxy-fuel (HVOF) sprayed hydroxyapatite (HA) splats and coatings were conducted in the present study as a function of the proportion of melting that occurred in HA particles during HVOF spray. In vitro behavior of single and folded HA splats in simulated body fluid was also investigated. Results showed that phase composition of as-sprayed HA coatings was influenced significantly by the melt fraction in HVOF sprayed particles. Melt fraction of the HA powders were experimentally determined from particle morphology analysis. It was found that the spray parameters and starting powder size influenced the melt fraction of the particles. In vitro investigation of individual HA splats made from different HA particles revealed decisive role of local phase composition in influencing their dissolution/precipitation behavior during the test. Furthermore, Raman spectroscopy qualitative inspection on the sprayed HA particles (partial melted) revealed that thermal decomposition occurred within the melted part rather than the unmelted zone. Young's modulus and micro-hardness of the as-sprayed particles and coatings were determined using nano-indentation technique. The resolidified zone of the sprayed HA particles exhibited an average Young's modulus value of 41.25 GPa. The measured values ranged from 23.1 to 65.3 GPa. The unmelted part of the HA powders showed a markedly narrower range. Young's modulus value of 83.9 GPa (+/-9.4 GPa) was recorded for this region. This succinctly highlight the difference between the unmelted region and melted regions of a HA particle. Young's moduli values measured on HVOF coatings were found to mirror the trend found in the spheroidised particles and splats with apt fidelity.