Effects of microstructure on the corrosion behavior of CoCr porous coatings on orthopedic implants

Cobalt-chromium alloy porous coatings have become increasingly popular as a means of achieving a stable, longer lasting fixation on orthopedic implants. However, sintering heat treatments cause changes in the microstructure that result in changes in the corrosion behavior of the porous coatings. Experiments were conducted to examine the effects of microstructure on the corrosion of CoCr porous coatings. Four distinct microstructures were characterized. Light microscopy revealed microstructures A and B had relatively fewer carbides and a large-grain structure, microstructures C and D displayed a finer grain size with significant carbide formation, predominantly within grains and fusion zones. Accelerated anodic corrosion experiments were conducted to study the localized attack of each microstructure. Experiments were conducted using metallographically polished porous-coated disks for durations of 1, 4, 16, 24, and 72 h. The disks were examined with SEM and EDS to observe preferential attack and element depletion. Results showed a progressive dissolution of the matrix, with preferential attack of the grain boundaries and regions adjacent to the carbides due to sensitization. A precipitation layer was found to be Cr-rich and possibly composed of chromium hydroxide or a chromium orthophosphate. In addition, the solution became yellow in color with longer exposure times, possibly due to the presence of chromate ions, as indicated by an increased chromium level detected by AAS.