Proposal to join the research project composite Bio-Ceramic Coatings applied on Titanium Implants by the Cold Spraying Technology icon

Proposal to join the research project composite Bio-Ceramic Coatings applied on Titanium Implants by the Cold Spraying Technology




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НазваProposal to join the research project composite Bio-Ceramic Coatings applied on Titanium Implants by the Cold Spraying Technology
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powerpluswatermarkobject357831064ONU Centre “Innovation office” PROPOSAL TO JOIN THE RESEARCH PROJECT

Composite Bio-Ceramic Coatings applied on Titanium Implants by the Cold Spraying Technology

Project Highlights


Abstract

Several thermal spray technologies, such as Plasma Spray and High Velocity Oxy‐Fuel (HVOF) have been utilized in order to apply Hydroxyapatite (HA) coatings onto titanium alloys for biomedical applications. A dilemma arises when using thermal spray techniques to apply Bioceramic coatings such as HA, these techniques require significant processing temperatures in order to provide sufficient particle melting to achieve an appropriate coating thickness. This melting often leads to changes in physical and chemical properties of the HA resulting in unknown variations in the coating´s biocompatibility. A process such as Cold Gas Dynamic Spray or simply Cold Spraying can be utilized to provide coatings of HA, as melting or even significant heating of the feedstock particles is not required.


Cold Spraying offers an innovative deposition process for both ceramics and metals. This line of sight, solid‐state process utilizes a supersonic gas stream to accelerate particles beyond a critical velocity. These unheated particles, upon impact with a substrate will plastically deform to create a coating. To date, difficulties have been arisen to acquire adequate coating thickness when spraying ceramics due their brittle nature. The goal of the project is to use early developments in Cold Spraying Technology and improve them to apply graded and coatings with significant thickness of ductile biomedical materials (Ti, as an example) and HA. The project could enhance the success rate of metallic implants by increasing the implant/host tissue interfacial strength and stability, particularly in case of hip joint implants, reducing both implant failure rate and the need for revision surgery.


^ Introduction / State of the art

Hydroxyapatite (HAP) coatings are applied to bioinert implants to encourage the establishment of a positive material connection to bone, with no soft tissue between the implant and bone. Titanium (Ti) and Ti alloys are the metals of choice for fabricating orthopedic and dental implants due to their light weight and strong mechanical properties as well as their ability to be biocompatible within the body. However, titanium is not such bioactive, increasing the possibility of implants loosening over a long period of time (Willmann 1999). To date most HA coatings are applied by the plasma of HVOF thermal spray processes. These processes either melt or soften the HA feedstock powder particles in order for them to deform enough on the impact with the substrate. One problem arising when using these processes is that the heating of the HAP feedstock particles often leads to changes in chemical composition (losing its biocompatibility) as well in mechanical properties, resulting in a non‐homogenous bone bonding around the implant and/or delamination of fragments from the coating materials, resulting in implant’s failure (Cheang P. 2002).

HAP powders can be cold sprayed simultaneously with titanium to form thick biocompatible composite coatings, without compromising the phase constituents of HAP; the adhesion strength of this composite coatings generated with the Cold Spraying Technology compared or exceeded the reported values of comparable plasma sprayed coatings (A. Choudhuri 2009).


Objectives

The primary objective of the project is the successful creation of High Density and Good Thickness Bioceramic Composite Coatings on different shape Titanium Implants substrates, all done utilizing a Cold Spraying System and Micro/Nano Powder Materials.

^ Research Area


Cold Spraying Process Improvement

Since the Cold Spraying process is only suitable for spraying ductile materials; brittle materials like ceramics, must be co-cold sprayed with a composite powder stock using a ductile metal as a matrix. Research on Metal/Ceramic Composites Cold Spraying must be done for successful results. The main tasks on this research are:

- Development of Nozzles for Metal/Ceramic Composite powder deposition.

- Research on multi-particle impacts of Metal/Ceramic Composite Powders on non-planar titanium substrates.

- Development of methodologies for cold spraying on titanium implants.


^ Biological Testing of the Coatings

Once the coatings will be generated, the implementation of the research results is crucial for the project dissemination. Is that for tests for the coatings Bio-compatibility, Degradation in Body Fluid, Wear/Biological Response to Wear Particles, Protein Absorption, Bacterial Adhesion, Blood Compatibility, Soft and Hard Tissue Response and other biological responses not tested in mechanical labs.


Materials

- Titanium Hip or Shoulder Implants under ISO 10993 specifications

- Cold Spraying System

- Equipment for Surface Preparation (Milling, Grinding/Polishing Machines)

- HAP powder under the ASTM F1581, ASTM F1185 standards with sizes below 40µm

- Titanium Powder with sizes over 40µm

- Coating Characterization Equipment for testing mechanical and micro structural properties (Microscopes, Adhesion Testing Equipment, Equipment for Metallographic Studies, Micro/Macro Hardness Tester, etc.)

- Biological Testing Lab

- CFD Software

- Explicit FEM Software

- Statistical Analysis Software


^ Expected Impact


- Improving the biocompatibility and mechanical resistance of HAP composite coatings on titanium implants by the implementation of a high performance and environment friendly technology enhancing as well (1) the life cycle of installed titanium implants and (2) reducing the production cost of the implants.


Partners needed for the project


- Research Organizations with experience in production and design of titanium implants

- Research Organizations with experience and capability in Biological Testing of coatings

- Research Organization with experience in implementation of biomechanical devices

- Industrial partners involved in orthopedic implants production


Contacts:

Iryna Nyenno, PhD of Economic Science,

Head of the Centre "Innovation Office"

of Odessa I.I. Mechnikov National University

inyenno@onu.edu.ua

www.innocentre.onu.edu.ua

+38 050 585 65 74



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