A biodegradable AZ91 magnesium alloy coated with a thin nanostructured hydroxyapatite for improving the corrosion resistance

Magnesium-based alloys with adapted interfaces for bone implants and tissue engineering

Magnesium and its alloys are one of the most used materials for bone implants and tissue engineering. They are characterized by numerous advantages such as biodegradability, high biocompatibility and mechanical properties with values close to the human bone. Unfortunately, the implant surface must be adequately tuned, or Mg-based alloys must be alloyed with other chemical elements due to their increased corrosion effect in physiological media. This article reviews the clinical challenges related to bone repair and regeneration, classifying bone defects and presenting some of the most used and modern therapies for bone injuries, such as Ilizarov or Masquelet techniques or stem cell treatments. The implant interface challenges are related to new bone formation and fracture healing, implant degradation and hydrogen release. A detailed analysis of mechanical properties during implant degradation is extensively described based on different literature studies that included in vitro and in vivo tests correlated with material properties' characterization. Mg-based trauma implants such as plates and screws, intramedullary nails, Herbert screws, spine cages, rings for joint treatment and regenerative scaffolds are presented, taking into consideration their manufacturing technology, the implant geometrical dimensions and shape, the type of in vivo or in vitro studies and fracture localization. Modern technologies that modify or adapt the Mg-based implant interfaces are described by presenting the main surface microstructural modifications, physical deposition and chemical conversion coatings. The last part of the article provides some recommendations from a translational perspective, identifies the challenges associated with Mg-based implants and presents some future opportunities. This review outlines the available literature on trauma and regenerative bone implants and describes the main techniques used to control the alloy corrosion rate and the cellular environment of the implant.

Incorporation of Al2O3 and ZrO2 ceramics to AZ31 magnesium alloys composite coating using micro-arc oxidation method

In this research, a composite coating with Al₂O₃ and ZrO₂ particles have been applied on AZ31 magnesium alloy by micro-arc oxidation (MAO) technique. The alkaline electrolyte included a constant based composition and different composition of the Al₂O₃ and ZrO₂ additives. Microstructure observations reveal that the surface pores of composite coating reduced during addition of ZrO₂ and Al₂O₃ ceramic particles. The hardness of coating increased from about 380 for non-added to 620 MPa for Al₂O₃+ZrO₂ added coating and wear rate reduced about 8 times. Wettability of the coating increased by incorporation of Al₂O₃ and/or ZrO₂ particles while, Al₂O₃ is more effective than ZrO₂. Addition of the ceramic particles enhanced the hydrophilicity properties of surface in wettability test and a contact angle of 43° was obtained for coating including Al₂O₃+ZrO₂. The antibacterial properties of MAO coatings showed that S. aureus bacterium is more sensitive to the zirconia and alumina particle than S. typhimurium bacterium after 24 h of incubation.

Hydrothermal Microwave-Assisted Fabrication of Nanohydroxyapatite Powder and Optimization of Its Nanocomposite Coatings on Magnesium Alloy for Orthopedic Applications

Developing appropriate protecting coatings for Mg alloy applications is a challenging issue. Herein, nanohydroxyapatite (nanoHAP) powder was first fabricated by the simple hydrothermal microwave-assisted method. A direct current electrophoresis deposition (EPD) of nanoHAP composite coatings on Mg-3Zn-0.8Ca magnesium alloy was successfully executed. Three suspensions with HAP-dispersive resin solution (ETELAC) ratios (in wt %) of 5-5, 5-2.5, and 2.5-2.5 were chosen for optimizing the effect of applied voltage, deposition time, and stirring mode and rates on the EPD process. NanoHAP composite coatings were applied on each sample in single- and double-run depositions. The results revealed that the maximum weight gain on the coated samples was obtained in 5-5 suspension at 50 V under 150 rpm mechanical stirring rate. Surface examination indicated crack-free coating formation with varying grain sizes. Adhesion tests demonstrated high interconnection between the obtained nanocomposite coatings and the alloy substrate. Electrochemical evaluation measurements in SBF at 37 °C indicated that the corrosion resistance of any coated sample is always superior compared to that of the uncoated bare substrate. It was suggested that the EPD of nanoHAP/ETELAC composite coatings on Mg-Zn-Ca alloy can be a good solution for protecting the alloy from the attack of the aggressive ions bound in the SBF environment.

Durability and corrosion behaviors of superhydrophobic amorphous coatings: a contrastive investigation

We present two kinds of superhydrophobic AlNiTi amorphous coatings with concave and convex surface structures. The convex superhydrophobic surface displays higher water-repellence (157.6°), better corrosion resistance, and durability.

Enhanced corrosion resistance and reduced cytotoxicity of the AZ91 Mg alloy by plasma nitriding and a hierarchical structure composed of ciprofloxacin-loaded polymeric multilayers and calcium phosphate coating

Much effort has made to lessen the cytotoxicity and enhance the corrosion resistance of biodegradable magnesium alloys, for example, by depositing multilayered polymeric coatings containing hydroxyapatite. In this work, a hierarchical structure composed of ciprofloxacin (Cip)-loaded on polyacrylic acid (PAA) and poly (ethyleneimine) (PEI) as biocompatible polymeric multilayers and calcium phosphate coating as the top layer is formed by the sol-gel method on the AZ91 Mg alloy with an intermediate layer formed by nitrogen plasma immersion ion implantation. The thicknesses of the multilayered coating and nitrided layer (Mg₃ N₂ ) are 10 μm and 140 nm, respectively. The corrosion current density decreases by 95.6% and the corrosion potential in the polarization curve shifts to the positive direction by 23%. The passivation process which occurs at defects by deposition of corrosion products mitigates both galvanic and localized corrosion. Slight increase in the contact angle and surface free energy, enhanced corrosion resistance, and reduced cytotoxicity are observed from the multilayered structure. The better corrosion resistance enables better control of release of Cip. Biological assessment indicates that the antibacterial activity against Escherichia coli is improved by 100% after culturing for 24 hr and the cell viability and noncytotoxic behavior of the coated AZ91 are enhanced as well. The corrosion behavior and biological results suggest that the strategy of using a hierarchical structure composed of Cip-loaded polymeric multilayers in conjunction with an intermediate plasma nitrided layer has large potential in the development of biodegradable orthopedic implants made of Mg alloys.

Tunable Microstructure and Morphology of the Self-Assembly Hydroxyapatite Coatings on ZK60 Magnesium Alloy Substrates Using Hydrothermal Methods

Hydroxyapatite coatings have been widely used to improve the corrosion resistance of biodegradable magnesium alloys. In this paper, in order to manufacture the ideal hydroxyapatite (HA) coating on the ZK60 magnesium substrate by hydrothermal method, formation mechanism of enhanced hydroxyapatite (HA) coatings, influence of pH values of the precursor solution on the HA morphology, corrosion resistance and cytotoxicity of HA coatings have been investigated. Results show that the growth pattern of the HA is influenced by the local pH value. HA has a preferential c-axis and higher crystallinity in the alkaline environment developing a nanorod-like structure, while in acid and neutral environments it has a preferential growth along the a(b)-plane with a lower crystallinity, developing a nanosheet-like structure. The different morphology and microstructure lead to different degradation behavior and performance of HA coatings. Immersion and electrochemical tests show that the neutral environment promote formation of HA coatings with high corrosion resistance. The cell culture experiments confirm that the enhanced corrosion resistance assure the biocompatibility of the substrate-coating system. In general, the HA coating prepared in neutral environment shows great potential in surface modification of magnesium alloys.

Effect of TiO2 addition on adhesion and biological behavior of BCP-TiO2 composite films deposited by magnetron sputtering

The present investigation focuses on the deposition of biphasic calcium phosphate (BCP) and titania (TiO₂) composite films on Ti-6Al-4V substrates using radio frequency (RF) magnetron sputtering. Three different compositions such as 100% BCP, 25% TiO₂-75% BCP and 50% TiO₂-50% BCP films were fabricated, and the physical, mechanical and biological behaviors of the films were analyzed. Post deposition, the films were annealed at 700 °C for 2 h to induce the crystallinity and to study its effect on different properties. The wettability was found to be 95°(±3°) for 100% BCP, 73°(±2°) for 25% TiO₂-75% BCP and 35°(±1°) for 50% TiO₂-50% BCP films, indicating improvement in wettability with an increase of TiO₂ weight percent in the composite films. The value of critical load (L_c2) for 100 BCP film improved from 8.7 N to 14.8 N (25 TiO₂-BCP) and >19 N (50 TiO₂-BCP film), indicating improvement in bonding strength with TiO₂ addition. The fetal bovine serum (FBS) adsorption decreased from 7.11 ± 0.25 to 4.42 ± 0.17 μg/cm² with TiO₂ weight percent from 0 to 50%. Cell adhesion and proliferation significantly improved in 100% BCP, 25% TiO₂-75% BCP and 50% TiO₂-50% BCP films as compared to uncoated Ti-6Al-4V. The maximum cell proliferation was found on the surface of 50% TiO₂-50% BCP film (210.1 ± 6.5%) after 6 days of incubation. However, after annealing all the films exhibited less cell adhesion and cytocompatibility presumably due to change in composition. Globular apatite structure was observed on all modified surfaces after 7 days immersion in simulated body fluid (SBF); however, the growth rate was higher for 50 TiO₂-BCP films. All these results revealed that the addition of TiO₂ in BCP film (without annealing) is advantageous for improving the bonding strength as well as the bioactivity of implants, which can be used for long-term dental and orthopedic applications.

In vitro corrosion resistance of layer-by-layer assembled polyacrylic acid multilayers induced Ca-P coating on magnesium alloy AZ31

Biodegradable magnesium (Mg)-based alloys have aroused great concern owing to their promising characteristics as temporary implants for orthopedic application. But their undesirably rapid corrosion rate under physiological conditions has limited the actual clinical application. This study reports the use of a novel biomimetic polyelectrolyte multilayer template, based on polyvinylpyrrolidone (PVP) and polyacrylic acid (PAA) via layer-by-layer (LbL) assembly, to improve the corrosion resistance of the alloy. Surface characterization techniques (field-emission scanning electron microscopy, Fourier transform infrared (FTIR) spectrophotometer and X-ray diffractometer) confirmed the formation of biomineralized Ca-P coating on AZ31 alloy. Both hydrogen evolution and electrochemical corrosion tests demonstrated that the corrosion protection of the polyelectrolyte-induced Ca-P coating on AZ31 alloy. The formation mechanism of biomineralized Ca-P coating was proposed.

Corrosion Behavior of AZ91D Magnesium Alloy with a Calcium–Phosphate–Vanadium Composite Conversion Coating

A novel self-healing calcium–phosphate–vanadium (Ca–P–V) composite coating on Mg alloy was successfully fabricated through a chemical conversion method. The effects of the vanadium concentration on the anticorrosion property of the substrate were also tested. The Ca–P–V coating with the main composition of CaHPO4, Ca3(PO4)2, and Mg3(PO4)2, with some hydroxides of V(V) dispersed into it has a similar morphology to the single vanadium coating. The corrosion behaviour of the Ca–P–V coating was studied through the electrochemical tests and the scratch immersion test in 3.5 wt % NaCl solution. The results showed that the Ca–P–V coated samples not only exhibit good corrosion resistance property, but also show self-healing ability. The ions of Ca, P, and V released from the coating can migrate in the corrosion solution and form a new compound layer on the damaged zone.

Ion-substituted calcium phosphate coatings by physical vapor deposition magnetron sputtering for biomedical applications: A review

Coatings based on ion-substituted calcium phosphate (Ca-P) have attracted great attention in the scientific community over the past decade for the development of biomedical applications. Among such Ca-P based structures, hydroxyapatite (HA) has shown significant influence on cell behaviors including cell proliferation, adhesion, and differentiation. These cell behaviors determine the osseointegration between the implant and host bone and the biocompatibility of implants. This review presents a critical analysis on the physical vapor deposition magnetron sputtering (PVDMS) technique that has been used for ion-substituted Ca-P based coatings on implants materials. The effect of PVDMS processing parameters such as discharge power, bias voltage, deposition time, substrate temperature, and post-heat treatment on the surface properties of ion-substituted Ca-P coatings is elucidated. Moreover, the advantages, short comings and future research directions of Ca-P coatings by PVDMS have been comprehensively analyzed. It is revealed that the topography and surface chemistry of amorphous HA coatings influence the cell behavior, and ion-substituted HA coatings significantly increase cell attachment but may result in a cytotoxic effect that reduces the growth of the cells attached to the coating surface areas. Meanwhile, low-crystalline HA coatings exhibit lower rates of osteogenic cell proliferation as compared to highly crystalline HA coatings developed on Ti based surfaces. PVDMS allows a close reproduction of bioapatite characteristics with high adhesion strength and substitution of therapeutic ions. It can also be used for processing nanostructured Ca-P coatings on polymeric biomaterials and biodegradable metals and alloys with enhanced corrosion resistance and biocompatibility. STATEMENT OF SIGNIFICANCE: Recent studies have utilized the physical vapor deposition magnetron sputtering (PVDMS) for the deposition of Ca-P and ion-substituted Ca-P thin film coatings on orthopedic and dental implants. This review explains the effect of PVDMS processing parameters, such as discharge power, bias voltage, deposition time, substrate temperature, and post-heat treatment, on the surface morphology and crystal structure of ion-substituted Ca-P and ion-substituted Ca-P thin coatings. It is revealed that coating thickness, surface morphology and crystal structure of ion-substituted Ca-P coatings via PVDMS directly affect the biocompatibility and cell responses of such structures. The cell responses determine the osseointegration between the implant and host bone and eventually the success of the implants.

Magnesium Implants: Prospects and Challenges

Owing to their suitable mechanical property and biocompatibility as well as the technological possibility of controlling their high corrosion rates, magnesium and its alloys have attracted significant attention as temporary bio-implants. Though the ability of magnesium to harmlessly biodegrade and its inherent biocompatibility make magnesium alloys a suitable choice for a temporary implant, their high corrosion rates limit their practical application, as the implants can potentially corrode away even before the healing process has completed. Different approaches, such as alloying, surface modification, and conversion coatings, have been explored to improve the corrosion resistance of various magnesium alloys. However, the corrosion behavior of magnesium implants with and without a surface modification has been generally investigated under in-vitro conditions, and studies under in-vivo conditions are limited, which has contributed to the lack of translation of magnesium implants in practical applications. This paper comprehensively reviews the prospects of magnesium alloy implants and the current challenges due to their rapid degradation in a physiological environment. This paper also provides a comprehensive review of the corrosion mitigation measures for these temporary implants.

Degradation and biocompatibility of a series of strontium substituted hydroxyapatite coatings on magnesium alloys

Sr-HA coatings could simply improve the degradation and osteoblast response of Mg in a Sr-dose dependent manner.

The current trends of Mg alloys in biomedical applications-A review

Magnesium (Mg) has emerged as an ideal alternative to the permanent implant materials owing to its enhanced properties such as biodegradation, better mechanical strengths than polymeric biodegradable materials and biocompatibility. It has been under investigation as an implant material both in cardiovascular and orthopedic applications. The use of Mg as an implant material reduces the risk of long-term incompatible interaction of implant with tissues and eliminates the second surgical procedure to remove the implant, thus minimizes the complications. The hurdle in the extensive use of Mg implants is its fast degradation rate, which consequently reduces the mechanical strength to support the implant site. Alloy development, surface treatment, and design modification of implants are the routes that can lead to the improved corrosion resistance of Mg implants and extensive research is going on in all three directions. In this review, the recent trends in the alloying and surface treatment of Mg have been discussed in detail. Additionally, the recent progress in the use of computational models to analyze Mg bioimplants has been given special consideration. © 2018 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater 107B: 1970-1996, 2019.

Manipulating the degradation behavior and biocompatibility of Mg alloy through a two-step treatment combining sliding friction treatment and micro-arc oxidation

Manipulating the degradation rate of biomedical Mg alloys has always been a challenge. In this study, a two-step treatment including sliding friction treatment (SFT) and micro-arc oxidation (MAO) was adopted to acquire a unique Mg-based architecture containing three typical layers comprising a MAO coating/nanocrystalline (NC) layer/coarse-grained (CG) matrix. It was found that the modified topmost MAO coating possessed enhanced corrosion resistance, cytocompatibility and hemocompatibility. The intermediate NC layer sandwiched between the coating and CG matrix was an ideal transition layer capable of avoiding degradation rate upsurge caused by coating breakdown; meanwhile, it provided an effective reinforcing effect on the overall mechanical strength. More importantly, the corrosion resistance of these layers was ranked in the order: MAO coating > NC layer > CG matrix. This kind of gradually increasing corrosion rate of the three layers with depth renders the two-step treatment a promising approach to design Mg-based implants possessing controllable degradation rates.

Biocompatible hydrophilic brushite coatings on AZX310 and AM50 alloys for orthopaedic implants

Dicalcium phosphate dihydrate (DCPD) brushite coating with flake like crystal structure for the protection of AZX310 and AM50 magnesium (Mg) alloys was prepared through chemical deposition treatment. Chemical deposition treatment was employed using Ca(NO₃)₂·4H₂O and KH₂PO₄ along with subsequent heat treatment. The morphological results revealed that the brushite coating with dense and uniform structures was successfully deposited on the surface of AZX310 and AM50 alloys. The X-ray diffraction (XRD) patterns and Attenuated total reflectance infrared (ATR-IR) spectrum also revealed the confirmation of DCPD layer formation. Hydrophilic nature of the DCPD coatings was confirmed by Contact angle (CA) measurements. Moreover, electrochemical immersion and in vitro studies were evaluated to measure the corrosion performance and biocompatibility performance. The deposition of DCPD coating for HTI AM50 enables a tenfold increase in the corrosion resistance compared with AZX310. Hence the ability to offer such significant improvement in corrosion resistance for HTI AM50 was coupled with more bioactive nature of the DCPD coating is a viable approach for the development of Mg-based degradable implant materials.

Effect of Hydroxyapatite on the Mechanical Properties and Corrosion Behavior of Mg-Zn-Y Alloy

Mg-Zn-Y alloys with a long period stacking ordered (LPSO) phase are potential candidates for biodegradable implants; however, an unfavorable degradation rate has limited their applications. Hydroxyapatite (HA) has been shown to enhance the corrosion resistance of Mg alloys. In this study, Mg₉₇Zn₁Y₂-0.5 wt% HA composite was synthesized and solution treated at 500 °C for 10 h. The corrosion behavior of the composite was studied by electrochemical and immersion tests, while the mechanical properties were investigated by a tensile test. Addition of HA particles improves the corrosion resistance of Mg₉₇Zn₁Y₂ alloy without sacrificing tensile strength. The improved corrosion resistance is due to the formation of a compact Ca-P surface layer and a decrease of the volume fraction of the LPSO phase, both resulting from the addition of HA. After solution-treatment, the corrosion resistance of the composite decreases. This is due to the formation of a more extended LPSO phase, which weakens its role as a corrosion barrier in protecting the Mg matrix.