The contribution of coating microstructure to degradation and particle release in hydroxyapatite coated prostheses

Plasma-sprayed coatings of hydroxyapatite powder are widely used on hip replacements. Commercially, they are supplied by a large number of companies and thus offer different coating design philosophies. This study focuses on a retrieved prosthetic stem that exhibited coating loss on the femoral stem occurring concurrently with third-body wear. The purpose of the research was to establish possible links between the coating microstructure and the clinical findings. A coated stem and cup were sectioned and the cross section was prepared to reveal the coating microstructure. Characterization included X-ray diffraction, FTIR spectroscopy, and crystalline particle quantification within the coating. It was found that the coating has a high amorphous content that provides fast resorption. The amount of crystalline particles increased on the distal location of the stem, the threads of the acetabular shell, and was generally higher on the cup. Accelerated degradation illustrated how the coating may be a particle-generating source by preferential dissolution of the amorphous phase, possibly allowing liberation of crystalline areas and other particulates at the substrate-coating interface. Such particles mainly include the less soluble hydroxyapatide formed from unmelted particles in the plasma or recrystallisation in the coating, but may also include entrapped grit lodged in the substrate during the roughening process. This study accents the importance of coating microstructure in understanding coating resorption.