Development of plasma-sprayed bioceramic coatings with bond coats based on titania and zirconia

Bond coats for plasma-sprayed hydroxyapatite (HAp) coatings on Ti-6A1-4V hip endoprotheses are being developed for improved in vivo performance. Bond coat powders consisting of (i) CaO-stabilized zirconia, (ii) a eutectic composition of titania and non-stabilized zirconia, and (iii) titania were applied by atmospheric plasma spraying (APS) to Ti-6A1-4V-coupons and 100 microm-thick Ti-6A1-4V foils. Subsequently, a thick layer of HAp was sprayed onto the thin bond coats. Peel tests on Ti-6A1-4V foil/bond coat/HAp top coat assemblies revealed that titania and titania/ zirconia bond coats increased the peel adhesion strength in a statistically significant way from 22 N m(-1) (HAp without a bond coat) to >42 and 32 N m(-1), respectively. Microstructural investigations by SEM on cross-sections of coatings leached in simulated body fluid for up to 28 days led to the conclusion that the chemically very stable bond coats act as an improved chemical barrier against in vivo release of metal ions from the implant, as well as an improved adhesive bond by development of very thin well-adhering reaction layers, presumbly composed of perovskite, calcium dititanate, and/or calcium zirconate.