Characterization of the interface in the plasma-sprayed HA coating/Ti-6Al-4V implant system

The successful use of plasma-sprayed hydroxyapatite (HA) coatings on Ti-alloy implants for implant-to-bone fixation requires strong adherence of the ceramic coating to the underlying metal substrate. In this study, the metal-ceramic interface was evaluated using mechanical, chemical, and structural characterization methods. Evaluations of an HA-coated Ti-6Al-4V implant system using a modified short bar technique for interfacial fracture toughness determination revealed relatively low fracture toughness values. Additionally, conventional tensile bond strength testing indicated much lower values than previously reported. Using high resolution electron spectroscopic imaging, evidence of chemical bonding was revealed at the plasma-sprayed HA/Ti-6Al-4V interface, though bonding was primarily due to mechanical interlock at the interface. This study illustrates the benefits of, and the need for, a multilevel approach to evaluate and improve these plasma-sprayed ceramic-metal substrate interfaces.