Microplasma Deposition of Biocompatible Coatings Using an Intelligent Robotic System for Plasma Processing

Alontseva, Darya; Krasavin, A.; Аbilev, Мadi; Zhilkаshinova, Almira

doi:10.12693/aphyspola.136.310

Cited by 5 publications

(4 citation statements)

References 10 publications

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“…The production and research site, where experimental medical implants from titanium alloys are manufactured by CNC machines, operates at D. Serikbayev East Kazakhstan Technical University [18,20,21]. Titanium alloys are the preferred material for the production of orthopedic and dental prostheses.…”

Section: Materials and Research Methodsmentioning

confidence: 99%

“…The use of robotic MPS allows for precision coating deposition on complex-shaped implant parts, such as parts of elbow and hip replacements. In our previous papers [18][19][20][21][22], it was shown that robotic microplasma spraying can produce coatings on medical implants made of biocompatible titanium and hydroxyapatite materials with the desired porosity and roughness, meeting the requirements of international standards for implants for surgery in terms of coating adhesive strength [23], crystallinity and purity [24].…”

Section: Introductionmentioning

confidence: 99%

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Fabrication and Characterization of Zr Microplasma Sprayed Coatings for Medical Applications

Voinarovych

Alontseva

Kyslytsia

et al. 2021

Advances in Materials Science

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This paper presents new results of studying the influence of parameters of microplasma spraying (MPS) of Zr wire on the structure of Zr coatings. The coating experiments were accomplished in a two level fractional factorial design. Individual particles of sprayed Zr wire and their splats on the substrate were collected under various spraying parameters (amperage, spraying distance, plasma gas flow rate and wire flow rate) and evaluated by Scanning Electron Microscopy (SEM) to establish the effect of particle size and shape on the coating microstructure. The particles were characterized by measurement of their sizes and the obtained results were evaluated in terms of their degree of melting. This was compared with the experimentally observed coating microstructure type and finally correlated to the investigated coating porosity to select the specific MPS parameters of Zr coatings depositing onto medical implants from Ti alloy. It was found that the main parameters influencing the size of the sprayed Zr particles and the porosity of the Zr coatings are the plasma gas flow rate and amperage. It was demonstrated that it is possible to control the porosity of Zr microplasma coatings in the range from 2.8% to 20.3% by changing the parameters of the MPS. The parameters of microplasma spraying of Zr wire were established to obtain medical implant coatings with porosity up to 20.3% and pore size up to 300 μm.

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Section: Materials and Research Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Fabrication and Characterization of Zr Microplasma Sprayed Coatings for Medical Applications

Voinarovych

Alontseva

Kyslytsia

et al. 2021

Advances in Materials Science

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“…3D scanning and AM technologies facilitate the fabrication of custom-designed implants with complex geometries, and robotic plasma spraying is used for coating. The authors of this review article have experience with successful robotic MPS of biocompatible titanium and HA coatings onto CNC-machined titanium alloy orthopedic implants [33][34][35]97] and on trabecular surfaces of additively manufactured titanium implants (particularly by the SLM method) [19].…”

Section: Thermal Plasma Spraying Of Metal-ceramic Coatingsmentioning

confidence: 99%

A Brief Review of Current Trends in the Additive Manufacturing of Orthopedic Implants with Thermal Plasma-Sprayed Coatings to Improve the Implant Surface Biocompatibility

et al. 2023

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The demand for orthopedic implants is increasing, driven by a rising number of young patients seeking an active lifestyle post-surgery. This has led to changes in manufacturing requirements. Joint arthroplasty operations are on the rise globally, and recovery times are being reduced by customized endoprostheses that promote better integration. Implants are primarily made from metals and ceramics such as titanium, hydroxyapatite, zirconium, and tantalum. Manufacturing processes, including additive manufacturing and thermal plasma spraying, continue to evolve. These advancements enable the production of tailored porous implants with uniform surface coatings. Coatings made of biocompatible materials are crucial to prevent degradation and enhance biocompatibility, and their composition, porosity, and roughness are actively explored through biocompatibility testing. This review article focuses on the additive manufacturing of orthopedic implants and thermal plasma spraying of biocompatible coatings, discussing their challenges and benefits based on the authors’ experience with selective laser melting and microplasma spraying of metal-ceramic coatings.

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“…Varying MPS parameters following the matrix of the factorial experiment make it possible to select a combination of spraying parameters that ensures the formation of coatings with specified porosity values [22,23]. The use of a robotic MPS allows for the precise spraying of coatings on implants of complex shapes, moving the plasma source at a constant modulus speed along a 3D trajectory along the surface of the implant with precise adherence to the spraying distance and a plasma jet perpendicular to the surface [23,33]. Previous papers [22,34] have shown that by using robotic microplasma spraying of commercially pure titanium and hydroxyapatite coatings on medical titanium implants, it is possible to obtain coatings with the desired levels of porosity and roughness and satisfactory adhesion to the substrate, including coatings with 95% purity and 90% crystallinity from hydroxyapatite on 3D-printed trabecular Ti6Al4V alloy substrates.…”

Section: Introductionmentioning

confidence: 99%

Biocompatibility and Corrosion of Microplasma-Sprayed Titanium and Tantalum Coatings versus Titanium Alloy

Alontseva,

Safarova (Yantsen),

Voinarovych

et al. 2024

Coatings

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This study investigates the in vitro biocompatibility, corrosion resistance, and adhesion strength of a gas abrasive-treated Ti6Al4V alloy, alongside microplasma-sprayed titanium and tantalum coatings. Employing a novel approach in selecting microplasma spray parameters, this study successfully engineers coatings with tailored porosity, roughness, and over 20% porosity with pore sizes up to 200 μm, aiming to enhance bone in-growth and implant integration. This study introduces an innovative methodology for quantifying surface roughness using laser electron microscopy and scanning electron microscopy, facilitating detailed morphological analysis of both the substrate and coatings. Extensive evaluations, including tests for in vitro biocompatibility, corrosion resistance, and adhesive strength, revealed that all three materials are biocompatible, with tantalum coatings exhibiting superior cell proliferation and osteogenic differentiation, as well as the highest corrosion resistance. Titanium coatings followed closely, demonstrating favorable osteogenic properties and enhanced roughness, which is crucial for cell behavior and attachment. These coatings also displayed superior tensile adhesive strengths (27.6 ± 0.9 MPa for Ti and 28.0 ± 4.9 MPa for Ta), surpassing the ISO 13179-1 standard and indicating a robust bond with the substrate. Our findings offer significant advancements in biomaterials for medical implants, introducing microplasma spraying as a versatile tool for customizing implant coatings, particularly emphasizing the superior performance of tantalum coatings in terms of biocompatibility, osteogenic potential, and corrosion resistance. This suggests that tantalum coatings are a promising alternative for enhancing the performance of metal implants, especially in applications demanding high biocompatibility and corrosion resistance.

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Microplasma Deposition of Biocompatible Coatings Using an Intelligent Robotic System for Plasma Processing

Cited by 5 publications

References 10 publications

Fabrication and Characterization of Zr Microplasma Sprayed Coatings for Medical Applications

Fabrication and Characterization of Zr Microplasma Sprayed Coatings for Medical Applications

A Brief Review of Current Trends in the Additive Manufacturing of Orthopedic Implants with Thermal Plasma-Sprayed Coatings to Improve the Implant Surface Biocompatibility

Biocompatibility and Corrosion of Microplasma-Sprayed Titanium and Tantalum Coatings versus Titanium Alloy

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