Search Results (63)

Hydroxyapatite (HA) has become a widely used material for bone grafting and surface modification of titanium-based orthopedic implants due to its excellent biocompatibility. Among various coating techniques, microplasma spraying (MPS) has gained significant industrial relevance. However, the clinical success of HA coatings also depends on their adhesion to the implant substrate. Achieving durable fixation and reliable biological integration of orthopedic implants remains a major challenge due to insufficient coating adhesion and limited osseointegration. This study addresses challenges in dental and orthopedic implantology by evaluating the microstructure, mechanical properties, and biological behavior of bilayer coatings composed of a zirconium (Zr) sublayer and an HA top layer, applied via MPS onto titanium alloy. Surface roughness, porosity, and adhesion were characterized, and pull-off and shear tests were used to assess mechanical performance. In vitro biocompatibility was tested using rat mesenchymal stem cells (MSCs) to model osteointegration. The results showed that the MPS-fabricated Zr–HA bilayer coatings achieved a pull-off strength of 28.0 ± 4.2 MPa and a shear strength of 32.3 ± 3.2 MPa, exceeding standard requirements. Biologically, the HA top layer promoted a 45% increase in MSC proliferation over three days compared to the uncoated titanium substrate. Antibacterial testing also revealed suppression of E. coli growth after 14 h. These findings support the potential of MPS-applied Zr-HA coatings to enhance both the mechanical integrity and biological performance of titanium-based orthopedic implants. Full article

The low hardness and insufficient wear resistance of aluminum and its alloys restrict their broader application in various fields. The application of surface protective coatings can effectively enhance the hardness and wear resistance of aluminum and its alloys. This article provides a comprehensive review of the recent research progress of wear-resistant coatings fabricated on aluminum and its alloys. The relevant achievements in the recent research works of preparing wear-resistant coatings by one-step methods (such as anodic oxidation, micro-arc oxidation, cold spraying, plasma spraying, and electrodeposition) and two-step methods (anodic oxidation and physical vapor deposition, micro-arc oxidation and sealing, magnetron sputtering, and plasma nitriding) are mainly introduced. The working principles of each coating preparation method, along with their impacts on the microstructure and tribological performance of the coatings, were systematically examined. Additionally, a comparative analysis was conducted to evaluate the advantages and disadvantages of each coating preparation method. Full article

This work presents an exhaustive parametric study of the multi-scale residual stress analysis on arbitrary substrate geometry based on a one-way-coupled thermo-mechanical model in an Atmospheric Plasma Spray process. It was carried out by modifying key process parameters, such as substrate surface geometry, substrate pre-heating temperature, and coating thickness, in an Al₂O₃ coating process on an aluminium substrate. The relationship of these parameters to the generation of quenching stress, thermal stress and residual stress was analysed at three different sub-modelling scales, from the macroscopic dimension of the substrate to the microscopic dimension of the splats. The thermo-mechanical phenomena occurring during the deposition process at the microscopic level were discussed in the proposed cases. Understanding these phenomena helps to optimise the parameters of the coating process by identifying the underlying mechanisms responsible for the generation of residual stresses. The simulated residual stresses of the 200 μm Al₂O₃ outer coated aluminium cylinder were experimental validated using the incremental high-speed micro-hole drilling and milling method. Full article

Titanium (Ti) and its alloys have attracted more interest, as they are widely employed as biomaterials due to their great biocompatibility, excellent strength ratio, and lightweight. However, corrosion occurs slowly due to an electrochemical reaction once the Ti material has been placed in the human body, contributing to infection and failure of implants in medical applications. Thus, the corrosion phenomenon has caused great concern in the biomedical field. It is desirable to make the surface modification to provide better corrosion resistance. The fabrication techniques of the coatings fabricated onto Ti and/or Ti alloy surfaces have been reported, including sol–gel, annealing, plasma spraying, plasma immersion ion implantation, physical vapor deposition, chemical vapor deposition, anodization, and micro-arc oxidation. This review first describes the corrosion types, including localized corrosion (both pitting and crevice corrosion), galvanic corrosion, selective leaching, stress corrosion cracking (SCC), corrosion fatigue (CF), and fretting corrosion. In the second part, the effects of corrosion on the human body were discussed, and the primary cause for clinical failure and allergies has been identified as the excessive release of poisonous and dangerous metal ions (Co, Ni, and Ti) from corroded implants into bodily fluids. The inclusion and exclusion criteria during the selection of literature are described in the third section. In the last section, we emphasized the current research progress of Ti alloy (particularly Ti6Al4V alloy) coatings in biomaterials for medical applications involving dental, orthopedic, and cardiovascular implants for anticorrosive applications. However, there are also several problems to explore and address in future studies, such as the release of excessive metal ions, etc. This review will draw attention to both researchers and clinicians, which could help to increase the coatings fabricated onto Ti and/or Ti alloy surfaces for anticorrosive applications in biomaterials for medical applications. Full article

This study investigates the microplasma deposition of molten tantalum (Ta) onto a rotating Grade 5 Ti Extra-Low Interstitial (ELI) alloy, producing multilayer film coatings with a porous microstructure. Optimal parameters for microplasma spraying Ta were experimentally determined to improve the surface properties of elbow joint implants. The physical and mechanical properties of the Grade 5 Ti ELI substrate and the Ta-based coating were analyzed. Moreover, mathematical modeling was utilized to determine the optimal parameters for the plasma coating process, including key factors such as spray distance, current, and rotational speed, which were systematically applied across three experimental series. A Ta coating thickness of 250 μm was achieved at 35 A current, 410 mm spray distance, and 7 rpm rotation speed under optimized deposition conditions. The results showed a microhardness increase on the Ta-coated surface, peaking above HV1000 with an average of HV742, while the Ti substrate averaged HV325. Additionally, the XRD patterns revealed the presence of metallic Ta alongside Ta oxides, such as Ta₂O and Ta₂O₅, in the Ta coatings. Full article

The Satsuma mandarin, a prominent fresh citrus variety cultivated in Asia, is susceptible to fruit cracking, a physiological disorder that significantly impacts yield and economic efficiency. This phenomenon occurs during the fruit expansion phase. The present study sought to further elucidate the correlation between citrus fruit cracking and fruit peel development or mineral elements, as well as to propose efficacious management measures. The present experiment was conducted on Citrus unshiu Marc. cv. ‘Miyagawa Wase’ over two successive seasons—2022 and 2023. The dynamic changes in fruit morphology were recorded using calipers, and the peel strength was assessed via a Plus Texture Analyzer. Paraffin sectioning technology was used to observe the morphological structure of peel cells. At 10 days after full bloom (DAFB), the peel cells exhibited vigorous proliferation, and the fruit and peel thicknesses underwent rapid expansion. At 50–60 d after full bloom, the longitudinal and transverse diameters of the fruit exhibited a marked increase in the growth rate of the former over the latter. At 80 d after full bloom, both the peel thickness change and the fruit growth rate exhibited a marked deceleration, and the albedo layer cells began to show signs of perforation. The following two time points were preliminarily proposed as the key points for the control of citrus fruit cracking: key point one was 50–60 days after full bloom; and key point two was 80–90 days after full bloom. The nitrogen (N), phosphorus (P), and potassium (K) contents in the different orchards were measured via the semi-micro Kjeldahl nitrogen method, the molybdenum–antimony colorimetric method, and flame photometry, respectively. The determination of other mineral elements was conducted by means of inductively coupled plasma spectroscopy. Principal component analysis was employed to analyze the 21-parameter indices of mineral elements in soil and leaf samples from the three orchards with different levels of fruit cracking. The study found that high concentrations of leaf Fe, P, and soil Cu, as well as organic matter content, contributed negatively to the extent of fruit cracking. The impact of diverse control measures on the incidence of fruit cracking was subsequently observed, following the implementation of tree crown spray treatments. The application of 0.5% calcium superphosphate and 0.006% EDTA-Fe, in combination with 10 ppm GA₃ sprayed during two critical periods, significantly reduced fruit cracking and did not adversely affect the internal or external quality of the fruits. The study emphasises the necessity of customising management measures according to the developmental characteristics of citrus fruits, given the observed varietal and regional distinctions in susceptibility to cracking. These findings are pivotal for advancing research in the field of fruit cracking and promoting the healthy development of the industry. Full article

The spraying process affects the microstructure and service life of thermal barrier coatings. In this work, by changing the plasma-spraying process, the second-phase micron-agglomerated particles were introduced to prepare embedded micron-agglomerated particle thermal barrier coatings. Conventional thermal barrier coatings and embedded micron-agglomerated particle thermal barrier coatings were prepared by setting spraying process parameters with different powder feeding rates and distances between powder feeders. Sintering experiments and thermal cycling experiments were carried out on conventional thermal barrier coatings and embedded micron-agglomerated particle thermal barrier coatings. The effects of spraying process parameters on the microstructure and thermal cycle life of embedded micron-agglomerated particle thermal barrier coatings were systematically studied. Three machine learning models of BP, SVM, and GA-SVM were established to evaluate the relationship between spraying parameters and coating microstructure and thermal cycle life. The results show that the sintering resistance of the new thermal barrier coating is 500% higher than that of the conventional thermal barrier coating. When the distance between the two powder feeders is 35 mm and the powder feeder 1 rate is 12 g/min, the thermal cycle life of the coating is the best. When using machine learning model evaluation, the evaluation results of the three machine learning models have certain accuracy. Among them, the GA-SVM machine learning model has the best prediction effect and the smallest prediction error. The results of this paper provide a new paradigm for further preparation of thermal barrier coatings with high performance and long life. Full article

Metallic biomaterials in a solid form cause stress-shielding in orthopedic applications. Such implants also suffer from limited tissue attachment to become a part of the living system. In view of that, hydroxyapatite (HA) coating reinforced with titanium oxide (TiO₂) was deposited in a beta (β)-Titanium (Ti-35Nb-7Ta-5Zr) substrate by plasma spray. This allows us to exploit the best of the two materials, namely the relatively low modulus of β-Ti, together with the porous and bone-like structure/composition of the HA to facilitate cell growth. This is foreseen to be used as an implant, particularly for musculoskeletal-related disability. Detailed scanning electron microscopy (SEM) investigation shows the lamellar structure of the coating that is composed of different phases and some porosities. Transmission electron microscopy (TEM) confirms the co-existence of both the amorphous and crystalline phases that build up the coating structure. In situ micro-mechanical tests revealed that the HA-TiO₂ coating was low in strength and modules compared to that of the substrate material, together with lower ductility. The yield stress and modulus of elasticity of the coating were about 877 ± 174 MPa and 447 ± 24 MPa, respectively. In contrast, the beta (β)-Ti substrate possesses about 990 ± 85 MPa of yield stress and 259 ± 19 MPa modulus of elasticity. The deformation mechanism was also quite different, where the coating crumbled under compressive loading, featuring limited ductility with cleavage (brittle)-type fracture, and the substrate showed plastic flow of materials in the form of slip/shear planes with extended ductility. Full article

This paper presents a new method of path planning for an industrial robot manipulator that performs thermal plasma spraying of coatings. Path planning and automatic generation of the manipulator motion program are performed using preliminary 3D surface scanning data from a laser triangulation distance sensor installed on the same robot arm. The new path planning algorithm is based on constructing a function of the geodesic distance from the starting curve. A new method for constructing a geodesic distance function on a surface is proposed, based on the application of Discrete Exterior calculus methods, which is characterized by a high computational efficiency. The developed algorithms and their software implementation were experimentally tested with the robotic microplasma spraying of a protective coating on the surface of a jaw crusher plate, which was then successfully operated for crushing mineral-based raw materials. Full article

This manuscript highlights the behavior of biodegradable polymers (PLA and HD PLA Green) coated with two distinct bronze alloy powders, Metco 51F-NS (Cu 9.5Al 1.2Fe) and Metco 445 (Cu 9.5Al). The coating was realized on printed samples by using the Atmospheric Plasma Spray (APS) technique. The current investigation will explain the results related to the surface quality, micro-structure, morphology, and thermal and tribological properties. Thus, from a structural point of view, the most uniform deposition was obtained in the case of composite powder Metco 51F-NS. The thermal behavior of the samples coated with copper-based powder achieved stability up to temperatures slightly above 200 °C, with carbonization of the matrix structure taking place around 350 °C. The micro-indentation and scratch analysis responses were significantly influenced by the semicrystalline structure of the samples and the presence of the powder compounds. Based on the increased characteristics of the coated samples, the authors of the present paper consider that parts made of biodegradable polymers and coated with copper microparticles are appropriate for some applications which take place in adverse operating conditions. Full article

The distribution morphology and density of micro-agglomerated particles are the main microstructural characteristics of embedded micro-agglomerated particle thermal barrier coatings. The study of their effect on the sintering resistance of coatings can help to further improve the service life of thermal barrier coatings. Strain tolerance and thermal insulation performance are important evaluation indicators for the sintering resistance of thermal barrier coatings. In this study, embedded micro-agglomerated particle thermal barrier coatings were prepared by plasma spraying, and the distribution morphology and density of micro-agglomerated particles were analyzed and counted. Different simulation models were established to analyze the compressive stress and thermal stress of the coating, as well as the influence of the microstructure characteristics on the strain tolerance and thermal insulation performance of the coating. A machine learning model was established to evaluate the nonlinear relationship between the microstructure characteristics of the coating and its strain tolerance and thermal insulation performance. The results show that the horizontal angle of the micro-agglomerated particles in the coating has the most significant effect on the sintering resistance and is predicted using the PSO-SVM machine learning model. The predicted effects are the most important, and the coefficients of determination for strain tolerance and thermal insulation are as high as 0.988 and 0.945, respectively, indicating a strong correlation between the predicted and actual values. This research technique used experimental research-simulation computation-machine learning can be used to optimize the microstructure of coatings and guide the preparation of high-performance thermal barrier coatings. Full article

The rising demand for dental and orthopedic implants and their frequent aseptic loosening failure mode necessitate the drive to continue modifying implant surfaces to improve osseointegration outcomes. Plasma-sprayed hydroxyapatite coatings are widely used but are prone to delamination. This study involves a single-step anodization process utilizing a novel electrolyte to produce Mg-doped carbonated hydroxyapatite and tricalcium phosphate-containing coatings on four titanium alloy surfaces. XRD confirmed hydroxyapatite and tricalcium phosphate formation, with FTIR examination revealing carbonate substitutions indicative of bone-like apatite formation in each oxide. SEM analyses revealed micro- and nano-scaled surface features on each oxide. SEM and EDS analyses of the oxide coating cross-sections showed each group to be bi-layered with an inner titanium dioxide-rich layer and an outer hydroxyapatite/tricalcium phosphate-rich layer. The oxide layer adhesion quality was shown to be good on CPTi, TAV, and TiMo α + β implant alloy surfaces. Unfortunately, the anodization process also resulted in an undesirable and embrittling omega phase at the substrate–oxide interface due to the migration of molybdenum into the inner oxide. Nonetheless, the anodized coatings on the CPTi and TAV alloy substrates, which are the most widely used titanium alloys for implant applications, show much potential for improving future patient outcomes. Full article

In order to further improve the oxidation resistance of SiC-coated C/C composites used in extreme environments, TaSi₂ coatings were deposited on the surfaces of SiC-coated C/C composites by supersonic air plasma spraying (SAPS) with different spraying power parameters, under other fixed parameter (gas flow, power feed rate, spraying distance and nozzle diameter) conditions. The micro-structures and phase characteristics of the TaSi₂ coatings prepared with the four kinds of spraying powers (40 kW, 45 kW, 50 kW and 55 kW) were analyzed. Also, the inter-facial bonding strengths and fracture modes between the four TaSi₂ coatings and the SiC coating were studied. The results showed that with an increase in the spraying power, the morphologies of the TaSi₂ coatings appeared from loose to dense to loose. When the spraying power was 50 kW, the deposition rate reached a maximum of 39.8%. The TaSi₂ coating presented an excellent micro-structure without obvious pores and microcracks, and its inter-facial bonding strength was 15.3 ± 2.3 N. Meanwhile, the fracture surface of the sample exhibited a brittle characteristic. Full article

Carbon fiber-reinforced plastics (CFRPs) have broad applications as lightweight structural materials due to their remarkable strength-to-weight ratio. Aluminum is often used as a bond coating to ensure adhesion between CFRPs and further coatings with a higher melting temperature. However, challenges persist in optimizing their surface properties and adhesion attributes for diverse applications. This investigation explores the impact of sandblasting and plasma pretreatment on CFRP surfaces and their influence on plasma-sprayed aluminum coatings. Two distinct CFRP substrates, distinguished by their cyanate ester and epoxy resin matrices, and two different aluminum powder feedstocks were employed. Plasma pretreatment induced micro-surface roughening in the range of 0.5 µm and significantly reduced the contact angles on polished specimens. Notably, on sandblasted specimens, plasma-activated surfaces displayed improved wetting behavior, which is attributed to the removal of polymeric fragments and augmented fiber exposure. Aluminum splats show a better interaction with carbon fibers compared to a polymeric matrix material. The impact of plasma activation on the coating adhesion proved relatively limited. All samples with plasma activation had deposition efficiencies that increased by 12.5% to 34.4%. These findings were supported by SEM single-splat analysis and contribute to a deeper comprehension of surface modification strategies tailored to CFRPs. Full article

Yb-doped Y₂O₃ stabilized ZrO₂ (YbYSZ) coatings, developed through solution precursor plasma spraying (SPPS), are engineered to resist calcium–magnesium–alumino–silicate (CMAS) infiltration by leveraging their unique micro-nano structures. This provides superior anti-wetting properties, crucial for preventing CMAS penetration at high temperatures. The investigation focused on the structural and compositional changes in YbYSZ-SPPS coatings subjected to prolonged thermal exposure at 1300 °C. Results indicate that while the coatings undergo significant sintering, leading to densification and microstructural evolution, the elemental composition and phase stability remain largely intact after up to 8 h of heat treatment. Despite some reduction in CMAS resistance, the coatings maintained their overall protective performance, demonstrating the potential of SPPS coatings for long-term use in high-temperature environments where CMAS infiltration is a concern. These findings contribute to the development of more durable TBCs for advanced thermal protection applications. Full article