Fabrication and characterization of rod-like nano-hydroxyapatite on MAO coating supported on Mg-Zn-Ca alloy

The poor corrosion resistance of magnesium alloys is a dominant problem that limits their clinical application. In order to solve this challenge, micro-arc oxidation (MAO) was used to fabricate a porous coating on magnesium alloys and then electrochemical deposition (ED) was done to fabricate rod-like nano-hydroxyapatite (RNHA) on MAO coating. The cross-section morphology of the composite coatings and its corresponding energy dispersion spectroscopy (EDS) surficial scanning map of calcium revealed that HA rods were successfully deposited into the pores. The three dimensional morphology and scanning electron microscopy (SEM) image of the composite coatings showed that the distribution of the HA rods was dense and uniform. Atomic force microscope (AFM) observation of the composite coatings showed that the diameters of HA rods varied from 95 nm to 116 nm and the root mean square roughness (RMS) of the composite coatings was about 42 nm, which were favorable for cellular survival. The bonding strength between the HA film and MAO coating increased to 12.3 MPa, almost two times higher than that of the direct electrochemical deposition coating (6.3 MPa). Compared with that of the substrate, the corrosion potential of Mg-Zn-Ca alloy with composite coatings increased by 161 mV and its corrosion current density decreased from 3.36 × 10⁻⁴ A/cm² to 2.40 × 10⁻⁷ A/cm² which was due to the enhancement of bonding strength and the deposition of RNHA in the MAO pores. Immersion tests were carried out at 36.5 ± 0.5 °C in simulated body fluid (SBF). It was found that RNHA can induce the rapid precipitation of calcium orthophosphates in comparison with conventional HA coatings. Thus magnesium alloy coated with the composite coatings is a promising candidate as biodegradable bone implants.     

Biomimetic apatite induction on Ca-containing titania

To understand the apatite induction mechanism in SBF, Ca-containing titania film without CaTiO₃ phase was fabricated by micro-arc oxidation (MAO) at low voltage (230 V) in an electrolytic solution containing calcium acetate monohydrate. Macro-porous, Ca-containing titania film was formed on the titanium substrate and the oxidized layer was composed of anatase and rutile phase. When immersed in 1.5SBF, no apatite was induced in the MAO specimen similar to the CaTiO₃-containing titania. However, after hydrothermal treatment at 250 °C for 2 h, numerous precipitates, presumably calcium phosphates, were formed on the surface of the titania after 7 day immersion and titania surface was entirely covered with apatite after 14 days of immersion. This study clearly showed that Ca-containing titania has the capability to induce apatite in SBF and hydrothermal treatment plays a decisive role in apatite induction, particularly producing surface hydroxyl groups such as Ca–OH or Ti–OH.     

Characterization of calcium containing plasma electrolytic oxidation coatings on AM50 magnesium alloy

An attempt was made to produce calcium containing plasma electrolytic oxidation (PEO) coatings on AM50 magnesium alloy using an alkaline electrolyte. This study was performed in three alkaline electrolytes containing calcium hydroxide and sodium phosphate with three different mass ratios viz., 1:2.5, 1:5 and 1:7.5. All the three coatings produced were found to contain Ca and P in appreciable amounts. The concentration of P was found to be higher in the coatings obtained in the electrolytes with higher concentration of phosphate ions. Even though all the three coatings were found to be constituted with magnesium oxide and magnesium phosphate phases, X-ray diffraction analyses revealed that the phase composition was influenced by the phosphate ion concentration/conductivity of the electrolyte. Further, the PEO coating obtained in the 1:7.5 ratio electrolyte was found to contain di-calcium phosphate (monetite) and calcium peroxide phases, which were absent in the other two coatings. Potentiodynamic polarization studies performed in 0.1 M NaCl solution showed that the coatings obtained from the 1:5 ratio electrolyte possessed a superior corrosion resistance, which is attributed to the combined effect of thickness, compactness and phase/chemical composition of this coating.     

Cross-linked gelatin/nanoparticles composite coating on micro-arc oxidation film for corrosion and drug release

A composite coating which could control drug release and biocorrosion of magnesium alloy stent materials WE42 was prepared. This composite coating was fabricated on the surface of the micro-arc oxidation (MAO) film of the magnesium alloy, WE42, by mixing different degrees of cross-linked gelatin with well-dispersed poly(dl-lactide-co-glycolide) (PLGA) nanoparticles. The PLGA nanoparticles were prepared by emulsion solvent evaporation/extraction technique. Nano ZS laser diffraction particle size analyzer detected that the size of the nanoparticles to be 150-300 nm. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) was used to analyze the morphology of the nanoparticles and the composite coating. Potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) were used to evaluate the corrosion behavior of the composite coating. Drug release was determined by ultraviolet-visible (UV-vis) spectrophotometer. The corrosion resistance of the composite coating was improved by preventing the corrosive ions from diffusing to the MAO films. The drug release rate of paclitaxel (PTX) exhibited a nearly linear sustained-release profile with no significant burst releases.     

Effect of employing ultrasonic waves during pulse electrochemical deposition on the characteristics and biocompatibility of calcium phosphate coatings

In the present work, we investigated the effect of employing ultrasonic waves during pulse electrochemical deposition on surface topography, chemical composition and biocompatibility of calcium phosphate (Ca-P) coatings. The SEM and 3D AFM images showed that the anodized titanium surface was covered with the uniform and refined size of plate-like Ca-P crystals, when the ultrasonic treatment of the electrolyte with power of 60 W was carried out during deposition. In contrast, for the Ca-P; 0 W coating applied under only the magnetic stirring of the electrolyte, the microstructure was non-uniform and some Ca-P crystals with the larger size were randomly observed in different regions, causing a rougher surface. The FTIR results also revealed that employing the ultrasound increases the deposition of a coating involved in only the most stable Ca-P phase of carbonated hydroxyapatite (CHA). However, in the absence of ultrasound, besides the prominent phase of CHA, some less stable Ca-P phases like octa calcium phosphate (OCP) and brushite were also formed in the Ca-P; 0 W coating. The Ca-P; 60 W coating showed the higher ability for apatite biomineralization after a 7-day immersion in the simulated body fluid (SBF). This coating also provided a better surface for the cellular activity, as compared to the Ca-P; 0 W coating.     

In vitro corrosion behavior of Ti-O film deposited on fluoride-treated Mg-Zn-Y-Nd alloy

In this paper, a new composite coating was fabricated on magnesium alloy by a two-step approach, to improve the corrosion resistance and biocompatibility of Mg-Zn-Y-Nd alloy. First, fluoride conversion layer was synthesized on magnesium alloy surface by immersion treatment in hydrofluoric acid and then, Ti-O film was deposited on the preceding fluoride layer by magnetron sputtering. FE-SEM images revealed a smooth and uniform surface consisting of aggregated nano-particles with average size of 100 nm, and a total coating thickness of ∼1.5 μm, including an outer Ti-O film of ∼250 nm. The surface EDS and XRD data indicated that the composite coating was mainly composed of crystalline magnesium fluoride (MgF₂), and non-crystalline Ti-O. Potentiodynamic polarization tests revealed that the composite coated sample have a corrosion potential (E_corr) of −1.60 V and a corrosion current density (I_corr) of 0.17 μA/cm², which improved by 100 mV and reduced by two orders of magnitude, compared with the sample only coated by Ti-O. EIS results showed a polarization resistance of 3.98 kΩ cm² for the Ti-O coated sample and 0.42 kΩ cm² for the composite coated sample, giving an improvement of about 100 times. After 72 h immersion in SBF, widespread damage and deep corrosion holes were observed on the Ti-O coated sample surface, while the integrity of composite coating remained well after 7 d. In brief, the data suggested that single Ti-O film on degradable magnesium alloys was apt to become failure prematurely in corrosion environment. Ti-O film deposited on fluoride-treated magnesium alloys might potentially meet the requirements for future clinical magnesium alloy stent application.     

Development of phosphate inter layered hydroxyapatite coating for stainless steel implants

As zinc phosphate acts as a versatile material for potential biomedical applications, it was modified into a thin layer coating for orthopaedic applications in the present study. A unique layering system consisting of pure substrate (316L SS), thick Fe-Zn alloy layers, thin ZnP layer on which a hydroxyapatite (HA) layer, was developed and studied. The composition, surface morphology and corrosion resistance characteristics of the layering system was evaluated. The stability of the multi-layered coating system consisting of ZnP inter layer, was evaluated by subjecting to different extent of dissolution in aggressive physiological media followed by allowing for re-growth in simulated body fluid (SBF). The coating system revealed good stability.     

Corrosion behaviors in physiological solution of cerium conversion coatings on AZ31 magnesium alloy

In this paper, a non-toxic Ce-based conversion coating was obtained on the surface of bio-medical AZ31 magnesium alloys. The micro-morphology of the coating prepared with optimal technical parameters and immersed in physiological solution (Hank's solution) in different time was observed by scanning electron microscopy (SEM), composition of the cerium conversion coating and corrosion products in Hank's solution were characterized by X-ray photoelectron spectroscopy (XPS) and energy dispersive spectroscopy (EDS), respectively. In addition, the corrosion property in Hank's solution was studied by electrochemical experiment and immersion test. The results show that the dense Ce-based conversion coating is obtained on the surface of AZ31 magnesium alloys in optimal technical parameters and the conversion coating consists of a mass of trivalent and tetravalent cerium oxides. The cerium conversion coating can provide obvious protection of magnesium alloys and can effectively reduce the degradation speed in Hank's solution. Also the degradation products have little influence on human body.     

The corrosion properties of phosphate coating on AZ31 magnesium alloy: The effect of sodium dodecyl sulfate (SDS) as an eco-friendly accelerating agent

Sodium nitrite has been used as an accelerating agent in phosphating bath to improve its properties. However, it is well known that sodium nitrite is a carcinogenic component in phosphating sludge. In this study, it has been aimed to replace sodium nitrite by an environmentally friendly accelerating agent. To this end, sodium dodecyl sulfate (SDS) was used in phosphating bath to improve the phosphate coating formation on an AZ31 magnesium alloy. The effect of SDS/sodium nitrite ratio on the phosphated samples properties was also studied. Using field emission scanning electron microscope (FE-SEM), X-ray diffraction (XRD), direct current (DC) polarization and electrochemical impedance spectroscopy (EIS) the properties of phosphated magnesium samples were studied.Results showed uniform phosphate coating formation on the magnesium sample mostly in hopeite phase composition. In addition, a denser and less permeable coating can be obtained at these conditions. The corrosion resistance of the phosphated samples was superiorly improved using higher SDS concentration in the phosphating bath.     

Preparation and properties of super-hydrophobic coating on magnesium alloy

The super-hydrophobic coating was successfully fabricated on the surface of magnesium alloy AZ31 by chemical etching and surface modification. The surface morphologies, compositions, wettability and corrosion resistance of the coating were investigated with SEM, XPS, contact angle measurement and electrochemical method, respectively. It shows that the rough and porous micro-nano-structure was presented on the surface of magnesium alloy, and the contact angle could reach up to 157.3 ± 0.5° with sliding angle smaller than 10°. The super-hydrophobic coating showed a long service life. The results of electrochemical measurements showed that anticorrosion property of magnesium alloy was improved. The super-hydrophobic phenomenon of the prepared surface was analyzed with Cassie theory, and it finds that only about 10% of the water surface is contacted with the metal substrate and the rest 90% is contacted with the air cushion.     

Electroless plating of silver on cenosphere particles and the investigation of its corrosion behavior in composite silicon rubber

In this paper, silver coating on the surface of cenosphere particles was prepared by electroless plating method. The adhesion, oxidation resistance and corrosion resistance properties of silver coating mixed in silicone rubber were investigated. The corrosion characteristic of silver coating was evaluated by anodic polarization curves of the silicone rubber composite in sulfuric acid solution. The results showed that the silver coating on the surface of cenosphere particles was smooth and uniform. The silver film was not oxidized and peeling off during preparation of composite silicone rubber. The adhesion between the cenosphere particle and silver film was good enough. The anodic polarization curves of the silicone rubber composite showed typical activation and passivation transformation. The values of corrosion potential, the initiating passive potential and maintaining passivity potential of composites filled with different contents of Ag-coated cenosphere particles were the same and related to the nature of silver coating. The passive current density of composite increased with increase of the amount of Ag-coated cenosphere particles and was inversely proportional to the resistance of silicone rubber composite. The better the conductivity of silicone rubber composite is, the higher corrosion rate will be.     

In vitro bioactivity and biocompatibility of calcium phosphate cements using Hydroxy-propyl-methyl-Cellulose (HPMC)

In this study, the bioactivity and biocompatibility of new calcium phosphate bone cements (CPC) using Hydroxy-propyl-methyl-Cellulose (HPMC) was evaluated to understand the effect of HPMC on bone-bonding apatite formation and biocompatibility. In vitro bioactivity was investigated by incubating the CPC samples containing different ratios of HPMC (0%, 2% and 4% HPMC) in simulated body fluid (SBF) for 2, 7, 14 and 28 days. The formation of bone like apatite was confirmed on CPC surfaces by SEM and XRD analysis. Higher HPMC content of CPC showed faster apatite deposition in SBF. A high Ca ion dissolution profile was also reported with an increase of pH in all samples in SBF. The apatite formation ability of these CPC samples was found to be dependent on both surface chemistry and immersion time in SBF. The In vitro cytotoxicity test showed that the CPC samples with 4% HPMC were fairly cytocompatible for fibroblast L-929 cells. SEM images showed that MG-63 cells were successfully attached to the CPC samples and well proliferated.     

Chemical nature of phytic acid conversion coating on AZ61 magnesium alloy

Phytic acid (PA) conversion coating on AZ61 magnesium alloy was prepared by the method of deposition. The influences of pH, time and PA concentration on the formation process, microstructure and properties of the conversion coating were investigated. Scanning electron microscopy (SEM) was used to observe the microstructure. The chemical nature of conversion coating was investigated by energy dispersive X-ray spectroscopy (EDS) and Fourier transform infrared spectroscopy (FTIR) techniques. The corrosion resistance was examined by means of potentiodynamic polarization method. The adhesive ability was tested by score experiments. The results showed that the growth and microstructure of the conversion coatings were all obviously affected by pH, time and PA concentration. In 0.5 mg/ml PA solution with a pH of 5, an optimization conversion coating formed after 20 min immersion time by deposition of PA on AZ61 magnesium alloy surface through chelating with Al³⁺. It made the corrosion potential E_corr of sample shifted positively about 171 mV than that of the untreated sample, and the adhesive ability reached to Grade 1 (in accordance with GB/T 9286).     

Nanostructured bioactive glass-ceramic coatings deposited by the liquid precursor plasma spraying process

Bioactive glass-ceramic coatings have great potential in dental and orthopedic medical implant applications, due to its excellent bioactivity, biocompatibility and osteoinductivity. However, most of the coating preparation techniques either produce only thin thickness coatings or require tedious preparation steps. In this study, a new attempt was made to deposit bioactive glass-ceramic coatings on titanium substrates by the liquid precursor plasma spraying (LPPS) process. Tetraethyl orthosilicate, triethyl phosphate, calcium nitrate and sodium nitrate solutions were mixed together to form a suspension after hydrolysis, and the liquid suspension was used as the feedstock for plasma spraying of P₂O₅-Na₂O-CaO-SiO₂ bioactive glass-ceramic coatings. The in vitro bioactivities of the as-deposited coatings were evaluated by soaking the samples in simulated body fluid (SBF) for 4 h, 1, 2, 4, 7, 14, and 21 days, respectively. The as-deposited coating and its microstructure evolution behavior under SBF soaking were systematically analyzed by scanning electron microscopy (SEM), X-ray diffraction (XRD), inductively coupled plasma (ICP), and Fourier transform infrared (FTIR) spectroscopy. The results showed that P₂O₅-Na₂O-CaO-SiO₂ bioactive glass-ceramic coatings with nanostructure had been successfully synthesized by the LPPS technique and the synthesized coatings showed quick formation of a nanostructured HCA layer after being soaked in SBF. Overall, our results indicate that the LPPS process is an effective and simple method to synthesize nanostructured bioactive glass-ceramic coatings with good in vitro bioactivity.     

Effect of additives on structure and corrosion resistance of ceramic coatings on Mg–Li alloy by micro-arc oxidation

In order to improve the corrosion resistance of ceramic coatings formed on Mg–5mass%Li substrate by micro-arc oxidation (MAO) method, two kinds of additives (Na₂B₄O₇ and EDTA) were doped in Na₂SiO₃–Na₃PO₄ solution system. The surface and cross-section morphology feature, phase composition and elemental composition were examined by SEM, XRD and EDX, respectively. Corrosion resistance of ceramic coating was tested by electrochemical methods. It was revealed that all coatings were composed of MgO and Mg₂SiO₄, and had porous surface structure. Doping of additives had little effect on the elemental composition, while it influenced the morphological feature of the coating. The results of electrochemical tests showed that the coatings prepared in the solutions with additive had good corrosion resistance. The addition of EDTA to the solution made coatings thinner and more uniform which resulted in better general corrosion resistance. The addition of Na₂B₄O₇ to the solution made coatings much thicker and compacter, which improved the pitting corrosion resistance.     

Enhanced corrosion resistance and cellular behavior of ultrafine-grained biomedical NiTi alloy with a novel SrO-SiO2-TiO2 sol-gel coating

NiTi alloy has a unique combination of mechanical properties, shape memory effects and superelastic behavior that makes it attractive for several biomedical applications. In recent years, concerns about its biocompatibility have been aroused due to the toxic or side effect of released nickel ions, which restricts its application as an implant material. Bulk ultrafine-grained Ni50.8Ti49.2 alloy (UFG NiTi) was successfully fabricated by equal-channel angular pressing (ECAP) technique in the present study. A homogeneous and smooth SrO-SiO₂-TiO₂ sol-gel coating without cracks was fabricated on its surface by dip-coating method with the aim of increasing its corrosion resistance and cytocompatibility. Electrochemical tests in simulated body fluid (SBF) showed that the pitting corrosion potential of UFG NiTi was increased from 393 mV(SCE) to 1800 mV(SCE) after coated with SrO-SiO₂-TiO₂ film and the corrosion current density decreased from 3.41 μA/cm² to 0.629 μA/cm². Meanwhile, the sol-gel coating significantly decreased the release of nickel ions of UFG NiTi when soaked in SBF. UFG NiTi with SrO-SiO₂-TiO₂ sol-gel coating exhibited enhanced osteoblast-like cells attachment, spreading and proliferation compared with UFG NiTi without coating and CG NiTi.     

Investigation of plasma electrolytic oxidation process on AZ91D magnesium alloy

Ceramic coatings oxidized for different time periods were prepared to characterize the plasma electrolytic oxidation (PEO) process of AZ91D magnesium alloy. The coatings were analyzed using scanning electron microscopy, X-ray diffraction, X-ray photoelectron spectroscope and potentiodynamic polarization measurement. The results show that the PEO coatings perform different growth behaviors at different PEO stages, and different morphologies are exhibited on α- and β-phase of Mg substrate. The corrosion resistance measurement predicates that within the first 30 min oxidation, coating oxidized for 20 min is the best corrosion resistant.     

A method to select the optimal equivalent electrical circuit applied to study corrosion system of composite coating on magnesium alloy

Mg-Al layered double hydroxides/micro-arc oxidation (Mg-Al LDHs/MAO) composite coating on AZ31 magnesium alloy is fabricated by hydrothermal treatment. Corrosion system is described by ideal equivalent circuit, in which each layer or interface is regarded as the corresponding electronic component. The optimal equivalent circuit is determined by the minimum total error area of electrical parameters. Error areas of phase angle and modulus for experimental and fitting data are calculated for the selected four different kinds of circuit models such as EC1, EC2, EC3 and EC4. The results show that circuit model EC2 is the best because its total error is 1/2, 2/19 and 1/15 of error values for other three kinds of circuit models, respectively. This work reveals that the optimal equivalent electrical circuit can well reflect corrosion system of Mg-Al LDHs/MAO composite coating with the help of electrochemical impedance spectroscopy (EIS) and scanning electron microscope (SEM).     

Effects of structure and composition of the CaP composite coatings on apatite formation and bioactivity in simulated body fluid

The surface properties of biomaterials determine the interactions between biomedical devices and the surrounding biological environment. The surface modification of biomaterials is extensively recognized as a key strategy in the design of the next generation of bone implants and tissue engineering. In this study, the highly ordered octacalcium phosphate (OCP) coating and OCP/protein coating with hierarchically porous structure in nano-micro scale were constructed on titanium substrate by electrochemically-induced deposition (ED). The formation behavior of apatite on OCP and OCP/protein coatings immersed in simulated body fluid (SBF) was investigated in physicochemical aspects. It is indicated that soaked in SBF, the OCP and OCP/protein coatings are possible to induce relevant apatite formation on their surface, and the apatite-forming behavior in body environment is depended on the chemical composition and structure of the coatings. The apatite formed on OCP/protein composite coating possesses carbonated structure, needle-like crystals in nano scale, lower Ca/P ratio and higher degree of the preferred c-axis orientation, which are similar to the mineral composition and structure in natural bone, and hence called as bone-like apatite.     

Apatite formation on Poly (vinyl alcohol)-coated Poly (?-caprolactone) films by incubation in simulated body fluids

In this study, biodegradable poly (?-caprolactone) (PCL) films were coated with poly (vinyl alcohol) (PVA) and then incubated in a simulated body fluid 1.5SBF to prepare an apatite (HA)/PCL composite. It was found that the bone-like apatite formability of PCL was enhanced by PVA coating. The changes of surface properties induced by PVA coating were effective for apatite formation. The apatite formability increased with increasing coating amount. After 24 h incubation, apatite was formed on PVA-coated PCL film but hardly any apatite was found on uncoated PCL plate. The surface chemistry of the specimens was examined using XPS, FT-IR-ATR. The apatite formed was characterized by using SEM, TF-XRD, FT-IR, EDS. The apatite formed was similar in morphology and composition to that of natural bone. This indicated that simple PVA coating on PCL substrate could serve as a novel way to accelerated apatite formation via biomimetic method.