Corrosion and Biocompatibility Studies of Bioceramic Alumina Coatings on Aluminum Alloy 6082

Recent advances in ceramic materials, particularly porous alumina (Al₂O₃), have significantly enhanced the safety and efficacy of medical implants by improving biocompatibility and modulating cellular behavior for biomedical applications. Variations in the surface structure and chemical composition of porous Al₂O₃ promote different biological responses and coating stability, underscoring the need for further biological and corrosion research. Traditional methods for producing alumina ceramics from powder are expensive, time-consuming, and limited in their ability to create complex shapes and large structures due to the brittleness of alumina. This study evaluates the biocompatibility of bioceramic-coated aluminum (Al) alloy 6082 as a lightweight and cost-effective alternative for bone osteosynthesis plates. Al₂O₃ coatings were achieved through anodization using phosphoric and sulfuric acids. The untreated and anodized alloys were analyzed for chemical stability and biocompatibility and compared with medical-grade titanium alloy. All specimens exhibited excellent biocompatibility, demonstrating high adhesion and viability of the fibroblast cell line. Corrosion resistance and metal ion release were assessed in simulated body fluid, with all specimens effectively suppressing the release of Fe and toxic Al ions. The untreated Al alloy exhibited a higher release of Mn ions than the coated specimens. Notably, the bioceramic coating obtained in sulfuric acid demonstrated 3 orders of magnitude higher corrosion resistance, indicating its potential suitability for biomedical applications. By addressing the limitations of traditional alumina ceramics, our approach enables the fabrication of products in diverse sizes and shapes, offering a practical solution for creating customized biomedical implants.