Curcumin and Vitamin C dual release from Hydroxyapatite coated Ti6Al4V discs enhances in vitro biological properties.

Titanium alloys are widely used as implant materials due to their biocompatibility and superior mechanical properties for high-load-bearing applications. However, one of the major challenges is their inferior bioactivity and osseoconductivity. Hydroxyapatite is widely used as an alternative material for bone implants due to its compositional similarity to natural bone. In this study, hydroxyapatite is coated on Ti6Al4V discs to enhance its bioactivity. The coated discs are drop-casted with curcumin in the lower layer and vitamin C in the upper layer. This study aims to evaluate the effects of this dual drug delivery system on osteoblast cell proliferation, inhibition of osteoclastogenesis, chemo-preventive and infection control properties. The coating strength obtained is 22 ± 2 MPa. The release from the dual delivery system shows a 1.5-fold increase in osteoblast cell viability, a 1.5-fold reduction in osteoclast cell differentiation, a 2-fold decrease in osteosarcoma growth. The release of curcumin demonstrates a 94% antibacterial efficacy, while the release of vitamin C exhibits an efficacy of 98.6% aganist Staphylococcus aureus. This multifunctional system can be used as a potential implant for load-bearing applications.

Microstructure and wear behaviour of AlCoCrFeNi-coated SS316L by atmospheric plasma spray process.

The capacity to endure harsh wear in demanding conditions in stainless steel drops under extreme nature and applications. Protecting the surface by providing a coating layer supports the usage in harsh conditions. In this work, SS316L is coated with AlCoCrFeNi high-entropy alloy (HEA) by atmospheric plasma spray process and annealed at 600°C for 2 hours. The AlCoCrFeNi HEA exhibited spherical particles with bcc phase and 20 µm particle size. The coating morphology revealed a uniform coating with a homogeneous distribution of HEA particles over a thickness of 150 µm. The coating post-annealing offered improved microhardness by 12% than the coated sample before annealing. The wear test was executed by varying load, sliding distance, and sliding velocity at normal temperature, 400°C and 600°C and the corresponding worn surface was analysed. The coated samples after annealing showed 57.6%, 87.5%, and 65.4% improved wear resistance at normal temperature than the coated sample before annealing at minimum levels of load, sliding velocity and distance. The wear rate of coated and annealed samples revealed 5.2%, 4.5%, and 4.4% better wear resistance at 400°C than the coated samples before annealing. The worn surface morphology showcased wear mechanisms to be delamination, abrasive wear, and oxide layer formation under all conditions.

The present work reports a novel study of plasma spraying of SS316L substrate using AlCoCrFeNi High-Entropy Alloy that marks the first attempt in analysing its hot wear performance.

Ensemble Methods for APS In-Flight Particle Temperature and Velocity Prediction Considering Torch Electrodes Ageing.

The nonlinear relationship between the input process parameters and in-flight particle characteristics of the atmospheric plasma spray (APS) is of paramount importance for coating properties design and quality. It is also known that the ageing of torch electrodes affects this relationship. In recent years, machine learning algorithms have proven to be able to take into account such complex nonlinear interactions. This work illustrates the application of ensemble methods to predict the in-flight particle temperature and velocity during an APS process considering torch electrodes ageing. Experiments were performed to record simultaneously the input process parameters, the in-flight powder particle characteristics and the electrodes usage time. Random Forest (RF) and Gradient Boosting (GB) were used to rank and select the features for the APS process data recorded as the electrodes aged and the corresponding predictive models were compared. The time series aspect of the multivariate APS in-flight particle characteristics data is explored. Two strategies of time series embedding are considered. The first one simply embeds the attributes and the targets from the previous n time segments considered without any modification; whereas the second strategy first performs differencing to make the time series stationary before embedding. For the present application, RF is found to be more suitable than GB since RF can predict both the in-flight particle velocity and temperature simultaneously, properly considering the interactions between the two targets. On the other hand, GB can only predict these two targets one at a time. The superior performance of both embedded predictive models and the feature rankings of them suggest that it is better to consider the APS data as time series for the in-flight particle characteristic prediction. In particular, it is demonstrated that it is advantageous to first make the time series stationary using the traditional differencing technique, even when modeling using RF.

Long-Term Potentiodynamic Testing and Tribometric Properties of Amorphous Alloy Coatings under Saline Environment.

Protective coatings for harsh environments are always welcome, but they must overcome profound challenges, including corrosion and wear resistance. The purpose of this study is to look into the long-term potentiodynamic polarization measurements and dry tribometric behavior of plasma-sprayed amorphous coatings on AISI 1035 mild steel. To investigate the impact of unique active polarization potentials on the electrochemical studies of the iron-based amorphous layer, which compares favorably to AISI 1035 mild steel, the active potential polarization curve and friction coefficient tests were performed. Scanning electron microscopy (SEM) and energy dispersive x-ray (EDX) analyses were used to investigate the coating's corrosion behavior. Their mechanical (Tribometric tests at higher sliding speeds) and chemical properties (electrochemical potentiodynamic polarization investigations) have also been thoroughly investigated. There is enough validation that these protective coatings can be used in hostile environments. The effects of long-term corrosion for 24 and 48 h were thoroughly examined. Tribometric examinations revealed that amorphous layers are highly resistant under dry conditions, as they offered a very low and stable friction coefficient less than 4 µ with micro Vickers hardness 1140 ± 22.14 HV, which is more than twice as compared to mild steel AISI 1035. The corrosion resistance of coatings in 3.5 wt % NaCl solution displays active transition characteristics of activation, passivation, over passivation, and pitting, as shown by the potentiodynamic polarization curves.

Microstructure and Properties of Atmospheric Plasma Sprayed (Al,Cr)2O3-TiO2 Coatings from Blends.

Coatings prepared from chromia-rich (Al,Cr)2O3 solid solution (ss) feedstock powders are intended to improve the properties of Cr2O3 coatings, but are rarely studied so far. In this work, the processability of a commercial (Al,Cr)2O3 solid solution (ss) powder containing 78 wt.% Cr2O3 by atmospheric plasma spraying (APS), the corresponding coating microstructures and properties were investigated. Possible further improvements were expected by blending with 2, 23 and 54 wt.% TiOx powder. For comparison, plain Cr2O3 and TiOx coatings were studied as well. The microstructures were analyzed using SEM, EDS and XRD measurements. Hardness (HV0.3) was measured, as well as the dry unidirectional sliding wear resistance and the abrasion wear resistance (ASTM G65). Moreover, the corrosion and electrical insulating properties were measured. The (Al,Cr)2O3 ss showed only a small change of the composition, and the formation of γ-Al2O3, as found for alumina-rich (Al,Cr)2O3 ss powders, was avoided. Compared to the plain chromia coating, some improvements of the processability and coating properties for the ss (Al,Cr)2O3 coating were found. The most balanced coating performance was achieved by blending the ss (Al,Cr)2O3 with 2 wt.% TiOx, as this coating showed both a high sliding and abrasion wear resistance, in combination with a high corrosion resistance.

Microstructure and Ablation Behavior of Low-Pressure Plasma Sprayed ZrB2 Coatings Down to 100 Pa.

The effect of chamber pressure on the microstructure and ablation behavior of ZrB2 coatings deposited by low-pressure plasma spraying was investigated. The results showed that as the spray chamber pressure further was reduced to less than 50 kPa, the porosity of the coating deposited at the same distance decreased with the chamber pressure, and the coating prepared under 100 Pa presented the lowest porosity of about 0.89%. The ablation performance test subjected to high-temperature plasma jet revealed that the linear ablation rate of ZrB2 coating increased with the porosity of the coating. As a result, among the ZrB2 coatings deposited at chamber pressures of 100 Pa, 5 kPa, 10 kPa and 50 kPa, the dense coating deposited at 100 Pa showed the lowest ablation rate of 0.33 µm/s. The dense ZrB2 coating with a thickness of about 100 µm was able to withstand 300 s ablation by a plasma flame with a net power of 25 kW resulting in an ablating coating surface temperature of about 2000 °C. The ablation mechanism of the coating was also examined.

Application of Image Segmentation to Identify In-flight Particles in Thermal Spraying.

In thermal spray process, the characteristics of in-flight particles (velocity and temperature) play an important role regarding the microstructure of the deposit and thus the coating performances. The implementation of diagnostic devices is necessary to measure such characteristics. Many imaging systems and algorithms have been developed for identifying and tracking in-flight particles. However, these current image systems have significant limitations in terms of accuracy for example. One key to solving the tracking problem is to get an algorithm that can effectively distinguish different particles in the same image frame at the same time. This study aims to develop an algorithm capable of identifying a large number of in-flight particles sprayed by thermal process. The results show that the noise and vignettes could be successfully treated, particles are clearly recognized in the background, leading to properly measuring the sizes and positions of the particle versus time. The proposed algorithm has a higher recognition rate and recognition range than other algorithms, which will provide a reasonable basis for subsequent calculation and processing.

Predicted Anode Arc Attachment by LTE (Local Thermodynamic Equilibrium) and 2-T (Two-Temperature) Arc Models in a Cascaded-Anode DC Plasma Spray Torch.

In DC plasma spray torches, anode erosion is a common concern. It mainly depends on the heat flux brought by the arc and on the dimensions and residence time of the arc attachment to a given location on the anode wall. The latter depend, to a great extent, on the attachment mode of the arc on the anode wall. This paper compares the anode arc attachment modes predicted by an LTE (Local Thermodynamic Equilibrium) and 2-T (two-temperature) arc models that include the electrodes in the computational domain. It deals with a commercial cascaded-anode plasma torch operated at high current (500 A) and low gas flow rate (60 NLPM of argon). It shows that the LTE model predicted a constricted anode arc attachment that moves on the anode ring, while the 2-T model predicted a diffuse and steady arc attachment. The comparison between the predicted and measured arc voltage showed that the 2-T prediction is closer to the actual voltage. Also, the post-mortem observation of a new anode ring of the actual plasma torch operated under the same conditions for a short time confirmed a diffuse arc attachment on a new anode.

Composite Si-Ni nanoparticles produced by plasma spraying physical vapor deposition for negative electrode in Li-ion batteries.

Si-Ni composite nanoparticles have been produced by a single and continuous plasma spray physical vapor deposition (PS-PVD) from Si and Ni powder feedstocks and their electrochemical performances as anode in lithium-ion batteries (LiB) are investigated. Si nanoparticles with 20-40 nm on which Ni is directly attached with Si/NiSi2epitaxial interface are formed spontaneously through co-condensation of high temperature elemental gas mixtures during PS-PVD. When only a little amount of Ni is added to Si, the effect of the epitaxial Ni attachment on the Si nanoparticles becomes evident; the cycle capacity is appreciably improved to reach a 1.6 times higher capacity than that of the Si only cell after 50 cycles, due to reduced charge-transfer resistance and nanosized Si particle. In contrast, excessive Ni addition to Si feedstock leads to formation of various silicides as a result of the accelerated silicidation during PS-PVD, which results in a significant decrease in the cycle capacity due to reduction of the active Si phase amount despite reduced charge-transfer resistance.

Evaluation and Characterization of a Durable Composite Phase Thermal Barrier Coating in Solid Particle Erosion and Burner Rig Tests.

A new concept of composite phase ceramic had been proposed for the topcoat of a durable thermal barrier coating (TBC) system which is one of the critical technologies for advanced turbine engines. The composite phase TBCs showed promising performance related benefits over conventional single phase TBCs, including durability, material affordability, thermal stability and low thermal conductivity. The present work is to continue the effort to exploring the TBC behaviors of erosive wear by solid particle erosion test and thermal cyclic shock by special burner rig test. In the erosion test, the investigation was focused on the most important characteristics of erosion test results using different characterization methods, including the variations of erosion damages with impingement angle and finally the effect of high temperature sintering. In the burner rig test, the TBC was exposed to a rapidly thermal cycling condition introduced by a high heat flux and high-velocity combustion torch. The TBC damages and failure modes were identified and explained in terms of microstructural observation and mechanism discussion. The composite phase c + t' TBC demonstrated improved erosion resistance relative to a Gd2Zr2O7 TBC and equivalent thermal shock resistance to a conventional 8YSZ TBC.

Antibacterial characteristics of thermal plasma spray system.

The objective of this study is to investigate antibacterial characteristics of a thermal plasma spray system. For this purpose, copper powder was coated on a handmade atmospheric plasma spraying system made by the stainless steel 316 substrate, which is preheated at different temperatures before spraying. A number of deposition characteristics such as antibacterial characteristics, adhesion strength and hardness of coating, was investigated. All of the spray parameters are fixed except the substrate temperature. The chemical composition was analyzed by X-ray diffraction (XRD). A scanning electron microscopy (SEM) and back scattering electron microscopy (BSE) were used to show the coating microstructure, its thickness and also the powder micrograph. The energy dispersive X-ray spectroscopy (EDX) was used to analyze the coating particles. Hardness of the deposition was examined by Vickers tester (HV0.1). Its adhesion strength was declared by cross cut tester (TQC). In addition, the percentage of bactericidal coating was evidenced with Staphylococcus aurous and Escherichia coli bacteria. Study results show that as the substrates temperature increases, the number of splats in the shape of pancake increases, the greatness and percentage of the deposition porosity both decrease. The increment of the substrate temperature leads to more oxidation and makes thicker dendrites on the splat. The enhancement of the substrate temperature also enlarges thickness and efficiency of coating. The interesting results are that antibacterial properties of coatings against the Escherichia coli are more than Staphylococcus aurous bacteria. However the bactericidal percentage of the coatings against Staphylococcus aurous and Escherichia coli bacteria roughly does not change with increasing the substrate temperature. Furthermore, by increment of the substrate temperature, coatings with both high adhesion and hardness are obtained. Accordingly, the temperature of substrate can be an important parameter for progressing mechanical properties of the antiseptic deposition.

Development of HA/Ag-NPs Composite Coating from Green Process for Hip Applications.

In the present study, biological hydroxyapatite (HA) was obtained from bovine bones through a thermal process. A total of 0% and 1% of silver nanoparticles (Ag-NPs) synthesized from Opuntia ficus (nopal) were added to the biological hydroxyapatite coatings using an atmospheric plasma spray (APS) on a Ti6Al4V substrate. Following this, its antimicrobial efficiency was evaluated against the following bacterial strains: Escherichia coli, Staphylococcus aureus, and Pseudomonas aeruginosa. This was conducted according to the Japanese Industrial Standard (JIS) Z2801:2000 "Antimicrobial Product-Test for Antimicrobial Activity and Efficacy". Scanning electron microscopy (SEM) showed that the silver nanoparticles (Ag-NPs) were evenly distributed on the coating surface. Energy dispersive X-ray spectroscopy (EDX) shows that apatite deposition occurs on a daily basis, maintaining a Ca/P rate between 2.12 and 1.45. Biocompatibility properties were evaluated with osteoblast-like cells (MC3T3-E1) by single-cell gel electrophoresis assay and Tali image cytometry.

Medical equipment antiseptic processes using the atmospheric plasma sprayed copper coatings.

Antibacterial surfaces such as copper coatings are able to reduce the growth of bacteria. In this study, copper coatings was deposited on the 316 stainless steel substrates by a handmade device operating as an atmospheric plasma spraying system. The chemical composition microstructure and morphology surface of the coatings are examined by x-ray diffraction (XRD) and scanning electron microscope (SEM) and back scattering electron microscope (BSE). Micro hardness as one of the key properties of the coating is characterized based on cross-section. We also evaluate the thickness and the adhesion strength of the coating. Dissection material of coating is performed by energy dispersive x-ray spectroscopy (EDX). Further, the antibacterial activity of our coatings is assessed by both gram negative Escherichia coli ATCC 10536 and gram positive Staphylococcus aureus PTCC 1112 bacteria. As the last step, the antibacterial performance of the coated stainless steel surface with copper are compared to uncoated one. Results confirm that the copper coatings improve the antibacterial property of substrates and owning fine antibacterial behavior compared to stainless steel.

Instantaneous formation of SiOx nanocomposite for high capacity lithium ion batteries by enhanced disproportionation reaction during plasma spray physical vapor deposition.

Nanocomposite SiOx particles have been produced by a single step plasma spray physical vapor deposition (PS-PVD) through rapid condensation of SiO vapors and the subsequent disproportionation reaction. Core-shell nanoparticles, in which 15 nm crystalline Si is embedded within the amorphous SiOx matrix, form under typical PS-PVD conditions, while 10 nm amorphous particles are formed when processed with an increased degree of non-equilibrium effect. Addition of CH4 promotes reduction in the oxygen content x of SiO x , and thereby increases the Si volume in a nanocomposite particle. As a result, core-shell nanoparticles with x = 0.46 as anode exhibit increased initial efficiency and the capacity of lithium ion batteries while maintaining cyclability. Furthermore, it is revealed that the disproportionation reaction of SiO is promoted in nanosized particles attaining increased Si diffusivity by two orders of magnitude compared to that in bulk, which facilitates instantaneous composite nanoparticle formation during PS-PVD.

Phosphor-Doped Thermal Barrier Coatings Deposited by Air Plasma Spray for In-Depth Temperature Sensing.

Yttria-stabilized zirconia (YSZ)-based thermal barrier coating (TBC) has been integrated with thermographic phosphors through air plasma spray (APS) for in-depth; non-contact temperature sensing. This coating consisted of a thin layer of Dy-doped YSZ (about 40 µm) on the bottom and a regular YSZ layer with a thickness up to 300 µm on top. A measurement system has been established; which included a portable; low-cost diode laser (405 nm); a photo-multiplier tube (PMT) and the related optics. Coating samples with different topcoat thickness were calibrated in a high-temperature furnace from room temperature to around 900 °C. The results convincingly showed that the current sensor and the measurement system was capable of in-depth temperature sensing over 800 °C with a YSZ top layer up to 300 µm. The topcoat thickness was found to have a strong effect on the luminescent signal level. Therefore; the measurement accuracy at high temperatures was reduced for samples with thick topcoats due to strong light attenuation. However; it seemed that the light transmissivity of YSZ topcoat increased with temperature; which would improve the sensor's performance at high temperatures. The current sensor and the measurement technology have shown great potential in on-line monitoring of TBC interface temperature.

A systematic review on the long-term success of calcium phosphate plasma-spray-coated dental implants.

The objectives of the current review were (1) to systematically appraise, and (2) to evaluate long-term success data of calcium phosphate (CaP) plasma-spray-coated dental implants in clinical trials with at least 5 years of follow-up. To describe the long-term efficacy of functional implants, the outcome variables were (a) percentage annual complication rate (ACR) and (b) cumulative success rate (CSR), as presented in the selected articles. The electronic search yielded 645 titles. On the basis of the inclusion criteria, 8 studies were finally included. The percentage of implants in function after the first year was estimated to be 98.4 % in the maxilla and 99.2 % in the mandible. The estimates of the weighted mean ACR-percentage increased over the years up to 2.6 (SE 0.7) during the fifth year of function for the maxilla and to 9.4 (SE 8.4) for the mandible in the tenth year of function. After 10 years, the mean percentage of successful implants was estimated to be 71.1 % in the maxilla and 72.2 % in the mandible. The estimates seem to confirm the proposed, long-term progressive bone loss pattern of CaP-ceramic-coated dental implants. Within the limits of this meta-analytic approach to the literature, we conclude that: (1) published long-term success data for calcium phosphate plasma-spray-coated dental implants are limited, (2) comparison of the data is difficult due to differences in success criteria among the studies, and (3) long-term CSRs demonstrate very weak evidence for progressive complications around calcium phosphate plasma-spray-coated dental implants.

High throughput production of nanocomposite SiO x powders by plasma spray physical vapor deposition for negative electrode of lithium ion batteries.

Nanocomposite Si/SiO x powders were produced by plasma spray physical vapor deposition (PS-PVD) at a material throughput of 480 g h-1. The powders are fundamentally an aggregate of primary ∼20 nm particles, which are composed of a crystalline Si core and SiO x shell structure. This is made possible by complete evaporation of raw SiO powders and subsequent rapid condensation of high temperature SiO x vapors, followed by disproportionation reaction of nucleated SiO x nanoparticles. When CH4 was additionally introduced to the PS-PVD, the volume of the core Si increases while reducing potentially the SiO x shell thickness as a result of the enhanced SiO reduction, although an unfavorable SiC phase emerges when the C/Si molar ratio is greater than 1. As a result of the increased amount of Si active material and reduced source for irreversible capacity, half-cell batteries made of PS-PVD powders with C/Si = 0.25 have exhibited improved initial efficiency and maintenance of capacity as high as 1000 mAh g-1 after 100 cycles at the same time.

Detection of segmentation cracks in top coat of thermal barrier coatings during plasma spraying by non-contact acoustic emission method.

Numerous cracks can be observed in the top coat of thermal barrier coatings (TBCs) deposited by the atmospheric plasma spraying (APS) method. These cracks can be classified into vertical and horizontal ones and they have opposite impact on the properties of TBCs. Vertical cracks reduce the residual stress in the top coat and provide strain tolerance. On the contrary, horizontal cracks trigger delamination of the top coat. However, monitoring methods of cracks generation during APS are rare even though they are strongly desired. Therefore, an in situ, non-contact and non-destructive evaluation method for this objective was developed in this study with the laser acoustic emission (AE) technique by using laser interferometers as a sensor. More AE events could be detected by introducing an improved noise reduction filter and AE event detection procedures with multiple thresholds. Generation of vertical cracks was successfully separated from horizontal cracks by a newly introduced scanning pattern of a plasma torch. Thus, generation of vertical cracks was detected with certainty by this monitoring method because AE events were detected only during spraying and a positive correlation was observed between the development degree of vertical cracks and the total AE energy in one experiment.

Characterization, mechanical properties, corrosion behavior and bone-like apatite formation ability of fluorine substituted hydroxyapatite coating.

Hydroxyapatite (HA) is a non-bioceramic commonly used in human implants in the form of coatings, which are limited in their application by mechanical and wear resistance properties, as well as biodegradability. In this study, fluorine substituted hydroxyapatite (FHA) coatings were prepared on Ti-6Al-4V surfaces by plasma spraying method using a mixture of calcium fluoride and hydroxyapatite powders. The prepared coatings were characterized by X-ray diffraction and fourier transform infrared (FTIR) spectroscopy at different levels of calcium fluoride (3 wt%, 6 wt%, 9 wt%, and 12 wt%). The biocompatibility of the coatings was evaluated by in vitro mineralization experiments. Experimental results showed that at 9 wt% of calcium fluoride, the prepared FHA coatings had better mechanical properties, with improved bond strength (28.2 MPa). The X-ray diffraction patterns of the coatings reflect the fluorine substitution during the spraying process and the 9FHA has the highest crystallinity according to the XRD analysis, which is closely related to the biological activity of the coating. In addition, Potentiodynamic polarisation showed that the sample coated with the 9FHA coating had the highest Ecorr and lowest Icorr, indicating the best corrosion resistance. The FHA coating exhibits faster apatite deposition in simulated body fluid, and the efficiency of apatite deposition increases with the increase of CaF2.

Electrochemical and hot corrosion behaviour of annealed AlCoCrFeNi HEA coating over steel.

The ability to endure extreme corrosion in challenging environments is reduced in stainless steel. This can be addressed by appropriate surface modification techniques to redefine the surface with the required properties. The characteristics of the atmospheric plasma sprayed AlCoCrFeNi High Entropy Alloy (HEA) on SS316l are presented in this study. The coating characterisation revealed uniform coating with homogeneous deposition of gas-atomized AlCoCrFeNi HEA spanning for 150 µm. The coated substrates were further annealed for 2 h at 400 °C, 550 °C, 700 °C and 850 °C and the annealing at 550 °C offered enhanced microstructure. Annealing the coated sample at 550 °C offered a 46% improvement in microhardness against the uncoated sample post-annealing. The electrochemical corrosion tests showcased improved corrosion resistance after annealing through the formation of a protective oxide layer and the influence of HEA. Hot corrosion tests at 900 °C resulted in 10.1%, 8.49%, and 10.36% improved corrosion resistance for the coated sample annealed at 550 °C than the coated sample pre annealing and 44.09%, 44.25%, and 42.09% than the uncoated sample pre annealing under three salt mixtures respectively. The microstructural analysis examines various corrosion modes and verifies the presence and formation of protective oxide layers.