Growth characteristics of micro-plasma oxidation ceramic coatings on Ti alloy by inductively coupled plasma-atomic emission spectrometer technique

The aim of this work was to study the growth characteristics of micro-plasma oxidation ceramic coatings on Ti-6Al-4V alloy. Compound ceramic coatings were prepared on Ti-6Al-4V alloy by pulsed micro-plasma oxidation (MPO) in NaAlO₂ solution. The phase composition and surface morphology of the coating were investigated by X-ray diffractometry and scanning electron microscopy. The solution of Ti from the substrate and the content of Al in the electrolyte were studied by inductively coupled plasma-atomic emission spectrometer (ICP-AES) technique. Ti from the substrate dissolved and came into the coating and the electrolyte during MPO process. The content of Ti in the electrolyte under the pulsed bi-polar mode was more than that of the pulsed single-polar mode. The phase composition and structure of the coating was attributable to the space steric hindrance of Al congregated on the electrode surface due to the effect of the electric field and the electrolyte characters. For the pulsed single-polar mode, the coating was mainly composed of a large amount of α-Al₂O₃ and a small amount of γ-Al₂O₃. And the coating was mainly structured by Al from the electrolyte. However, the coating was composed of a large amount of Al₂TiO₅ and a little α-Al₂O₃ and rutile TiO₂ for the pulsed bi-polar mode. And the coating was structured both by Ti from the substrate and Al from the electrolyte.     

Effects of duty ratio at low frequency on growth mechanism of micro-plasma oxidation ceramic coatings on Ti alloy

The aim of this work is to study the effects of duty ratio on the growth mechanism of the ceramic coatings on Ti-6Al-4V alloy prepared by pulsed single-polar MPO at 50 Hz in NaAlO₂ solution. The phase composition of the coatings was studied by X-ray diffraction, and the morphology and the element distribution in the coating were examined through scanning electron microscopy and energy dispersive spectroscopy. The thickness of the coatings was measured by eddy current coating thickness gauge. The corrosion resistance of the coated samples was examined by linear sweep voltammetry technique in 3.5% NaCl solution. The changes of the duty ratio (D) of the anode process led to the changes of the mode of the spark discharge during the pulsed single-polar MPO process, which further influenced the structure and the morphology of the ceramic coatings. The coatings prepared at D = 10% were composed of a large amount of Al₂TiO₅ and a little γ-Al₂O₃ while the coatings prepared at D = 45% were mainly composed of α-Al₂O₃ and γ-Al₂O₃. The coating thickness and the roughness were both increased with the increasing D due to the formation of Al₂O₃. The formation of Al₂TiO₅ resulted from the spark discharge due to the breakdown of the oxide film, while the formation of Al₂O₃ resulted from the spark discharge due to the breakdown of the vapor envelope. The ceramic coatings improved the corrosion resistance of Ti-6Al-4V alloy. And the surface morphology and the coating thickness determined the corrosion resistance of the coated samples prepared at D = 45% was better than that of the coated samples prepared at D = 10%.     

Synthesis of composite calcium-phosphate coatings via pulsed photon processing

The phase composition and mechanical properties of coatings generated on a Ti surface via the ion sputtering of a hydroxyapatite (HA) target and a compound (hydroxyapatite and Ti) target with subsequent pulsed photon processing (PPP) with incoherent xenon lamp radiation are investigated. It is found for the first time that pulsed photon processing accelerates the crystallization of amorphous films of Ca–P–O–H and Ca–P–O–H–Ti compositions, during which tricalcium phosphate Ca₃(PO₄)₂, titanium oxide TiO₂ (rutile, anatas), and perovskite CaTiO₃ are formed, depending on the radiation dose and the ratio between Ti and Ca phases (Ti/Ca) with hydroxyapatite structure. It is found that pulsed photon processing of initial amorphous coatings greatly increases their hardness (up to 10.9 GPa) and adhesion (up to 29.0 MPa).     

Effects of anodizing conditions on bond strength of anodically oxidized film to titanium substrate

The bond strength of the oxide film to the titanium substrate and its inherent structural characteristics are very important preconditions for the success of titanium implants. The purpose of this study was to evaluate the micro-morphologies, crystalline structures, and bond strengths of the anodically oxidized films formed on titanium with the variation of electrolytes and applied current densities. In contrast to the specimens produced using sulfuric acid as the electrolyte, those produced using phosphoric acid showed quite different shapes and densities of the pores as the applied current densities were varied. The oxide films anodized in sulfuric acid consisted of anatase and rutile TiO₂, whileTiP₂O₇ was predominantly formed on the Ti surfaces anodized using phosphoric acid as the electrolyte. The oxide films, which did not experience spark deposition showed amorphous shape and their bond strengths were significantly lower than those of the other groups (p < 0.05). Those specimens which experienced initial spark deposition with a low current condition showed the highest bond strengths (34.2 MPa) within each electrolyte sub-set. The growing rates of the oxide film thicknesses in relation to the electric current changes varied according to the type of electrolyte, and the oxide film thickness influenced the bond strength.     

Preparation and properties of titanium oxide film on NiTi alloy by micro-arc oxidation

Titanium oxide ceramic coatings were prepared by micro-arc oxidation (MAO) in galvanostatic regime on biomedical NiTi alloy in H₃PO₄ electrolyte using DC power supply. The surface of the coating exhibited a typical MAO porous and rough structure. The XPS analysis indicated that the coatings were mainly consisted of O, Ti, P, and a little amount of Ni, and the concentration of Ni was greatly reduced compared to that of the NiTi substrate. The TF-XRD analysis revealed that MAO coating was composed of amorphous titanium oxide. The coatings were tightly adhesive to the substrates with the bonding strength more than 45 MPa, which was suitable for medical applications. The curves of potentiodynamic porlarization indicated that the corrosion resistance of NiTi alloy was significantly improved due to titanium oxide formation on NiTi alloy by MAO.     

Preparation of ceramic coating on Ti substrate by plasma electrolytic oxidation in different electrolytes and evaluation of its corrosion resistance: Part II

The aim of this work is to discuss the growth characteristics and corrosion behavior of the prepared ceramic coatings on titanium by plasma electrolytic oxidation (PEO) technique in different electrolytes. PEO process was carried out on titanium under constant voltage regime using a pulse power supply. Three kinds of electrolytes, phosphate, silicate and borate based solutions, were used to evaluate the influence of electrolyte composition on the structure, surface morphology, phase composition and corrosion behavior of prepared ceramic oxide films (titania). The phase composition of the coatings was investigated by X-ray diffraction. Scanning electron microscopy was employed to evaluate the growth and surface morphology of coatings. Elements of coatings were investigated with energy dispersive spectrometer. Corrosion behavior of the coatings was also examined by potentiodynamic polarization and electrochemical impedance spectroscopy. The spark voltage of oxide films had a significant effect on the surface morphology, size and homogeneity of micro-pores, thickness and corrosion properties of coatings.     

Chemical treatment of TiO2-based coatings formed by plasma electrolytic oxidation in electrolyte containing nano-HA, calcium salts and phosphates for biomedical applications

TiO₂-based coatings were formed on titanium alloy by plasma electrolytic oxidation (PEO) in an electrolyte containing nano-HA, calcium salts and phosphates. Bioactive surface was formed after chemical treatment (NaOH aqueous solution) of the PEO coating. The surface of the PEO coating was mainly composed of Ti, O, Ca and P showing anatase and rutile; while that of the chemically treated PEO (CT-PEO) coating mainly contains Ti, O, Ca and Na showing anatase, rutile and amorphous phase. And the chemically treated surface exhibits dissolution of P and introduction of Na during the chemical treatment process. The chemical treatment has no effect on the chemical states of Ca and Ti of the PEO coating. In addition, the surface constituents of the CT-PEO coating show a uniform distribution near its surface with increasing depth. When incubated in a simulated body fluid for 7 and 14 days, the PEO coating does not exhibit apatite-forming ability; however, apatite was successfully deposited on the CT-PEO coating after 7 days probably due to the formation of hydroxyl functionalized surface, enhancing the heterogeneous nucleation of apatite. The addition of nano-HA in the electrolyte has effects on the surface character and apatite-forming ability of the PEO coating; however, it has no obvious influence on those of the CT-PEO coatings.     

Surface modification of pure titanium by hydroxyapatite-containing composite coatings

Micro-arc oxidation (MAO) is commonly applied to modify the surface of titanium (Ti)-based medical implants with a bioactive and porous Ti oxide (TiO₂) coating. The study reports a new method of incorporating hydroxyapatite (HA) within the TiO₂ coating by MAO and alkali heat treatment (AHT) in the solution containing Ca ion and P ion. The morphology, composition and phase composition of the coatings were analyzed with scanning electron microscopy with energy-dispersive X-ray spectrometer and X-ray diffraction. Surface topography and roughness of the coatings were investigated by atomic force microscopy operated in the tapping mode. The results showed that TiO₂-based coatings were obtained on pure Ti by MAO with an electrolyte containing Ca ion and P ion; the prepared MAO coatings were mainly composed of Ca, P, O and Ti. AHT transformed Ca and P to HA crystals. In conclusion, the TiO₂/HA composite coatings can be obtained on the surface of pure Ti by MAO and AHT, and the addition of Ca ion and P ion to the AHT solution contributed to the formation of HA.     

Corrosion and wear properties of PEO coatings formed on AM60B alloy in NaAlO2 electrolytes

Coatings with a thickness of 22-32 μm were formed on an AM60B magnesium alloy by plasma electrolytic oxidation (PEO) in electrolytes containing 12.0-24.0 g/l NaAlO₂ and other additives. SEM analyses of the coated samples showed that the coatings were compact with relatively low porosity. X-ray diffraction revealed that the coatings consisted of mainly MgAl₂O₄ and MgO phases. The relative amount of MgAl₂O₄ in the coating increased with increasing NaAlO₂ concentration. The relatively compact and thick coatings provide good corrosion protection for magnesium, as indicated by the results of potentiodynamic polarization tests. In addition, the PEO treatment also significantly improved the wear resistance of the alloy. Pin-on-disk wear tests showed that the PEO treatment reduced the wear volume loss by a factor of 10.     

Cobalt-containing oxide layers on titanium, their composition, morphology, and catalytic activity in CO oxidation

In this study possibility to form the layered compositions CoO_x + SiO₂/TiO₂/Ti by plasma electrolytic oxidation (PEO) method was shown. Compositions have been obtained by both one-stage PEO method (Method I) with addition of Co(CH₃COO)₂ into silicate electrolyte and impregnation of preliminary obtained by the PEO method SiO₂/TiO₂/Ti systems in aqueous solutions containing cobalt salts with their following annealing (Method II). XRD, XPS and SEM/EDX were used to investigate the phase and element composition, microstructure of the coatings prepared by the two various methods. Catalytic activity of the cobalt-containing composites was investigated in the CO oxidation reaction. Under experimental conditions, the structures obtained by impregnation and annealing method were more active, than those obtained by one-stage PEO method. The surface structures of cobalt-containing coatings obtained by the PEO method and by impregnation and annealing differ in both quantitative and qualitative relation. The cobalt content on the surface of impregnating coatings is three times as much as that for those formed by one-stage PEO method. It is found that coatings obtained by the Method II have a more developed surface. The surface of CoO_x + SiO₂/TiO₂/Ti compositions obtained by the PEO method contains, presumably Co(OH)₂ and Co₃O₄. The surface of the similar compositions obtained by the Method II, possibly contains CoO, either Co₂O₃, or CoOOH. The combination of these factors, perhaps, also provides a higher activity of the compositions formed by the Method II.     

Effect of NaAlO2 concentrations on microstructure and corrosion resistance of Al2O3/ZrO2 coatings formed on zirconium by micro-arc oxidation

In this study, Al₂O₃/ZrO₂ composite coatings were prepared on Zr substrates by micro-arc oxidation (MAO) in the NaAlO₂-containing electrolytes, and the effect of NaAlO₂ concentration on the microstructure, bond strength, microhardness and corrosion resistance of coatings was systematically investigated. The study reveals that the adequate NaAlO₂ in the electrolyte (>0.2 M) is essential to the formation of needle-like α-Al₂O₃ in the coatings, and the amount of α-Al₂O₃ rises with the increase of the NaAlO₂ concentration. m-ZrO₂ and t-ZrO₂ are present in all of the coatings, but their relative amount largely depends on the amount of Al₂O₃. It is also found that as the NaAlO₂ concentration increases from 0.2 to 0.3 M, the coating becomes denser and thicker, and its bond strength, maximum microhardness and corrosion resistance increases as well. The coating formed at 0.3 M NaAlO₂ demonstrates the highest bond strength of 52 MPa, the maximum microhardness of 1600 Hv_0.2N and the superior corrosion resistance. However, the overhigh concentration of NaAlO₂ (0.35 M) is found harmful to the coating's microstructure and properties.     

Effects of ultrasound on the evolution of plasma electrolytic oxidation process on 6061Al alloy

The plasma electrolytic oxidation (PEO) process of 6061Al alloy was carried out under the conditions with and without the assistance of ultrasound, respectively. The effects of ultrasound on the evolution of voltage, micro-discharge, morphology and composition of PEO coatings were investigated. The results show that ultrasound can greatly decrease the dielectric breakdown voltage of the coatings, increase the number of micro-discharges while decrease their average size, promote the evolution of micro-discharges, decrease the number and the average size of residual discharge pores in the coatings after 30 min of the process, promote the homogeneous distribution of elements and the formation of α-Al₂O₃ and 3Al₂O₃⋅2SiO₂ in the coatings.     

Stress dependence of growth mode change of epitaxial layered cobaltite γ-Na0.7CoO2

We report stress dependence of growth characteristics of epitaxial γ-Na_0.7CoO₂ films on various substrates deposited by pulsed laser deposition method. On the sapphire substrate, the γ-Na_0.7CoO₂ thin film exhibits spiral surface growth with multi-terraces and highly crystallized texture. For the γ-Na_0.7CoO₂ thin film grown on the (1 1 1) SrTiO₃ substrate, the nano-islands of ∼30 nm diameter on the hexagonal grains are observed. These islands indicate that the growth mode changes from step-flow growth mode to Stranski-Krastanow (SK) growth mode. On the (1 1 1) MgO substrate, the large grains formed by excess adatoms covering an aperture between hexagonal grains are observed. These experimental demonstrations and controllability could provide opportunities of strain effects of Na_xCoO₂, physical properties of thin films, and growth dynamics of heterogeneous epitaxial thin films.     

Properties of calcium phosphate coatings deposited by high-power ion beam ablation plasma

Biocompatible hydroxyapatite coatings (Ca₁₀(PO₄)₆(OH)₂) are used in stomatology and orthopedic surgery as an original structure for production of medical materials. These coatings have been deposited on Si, Ti and VT15-alloy substrates from ablation plasma formed under the impact of pulsed high-power ion beams on a calcium phosphate ceramic target. The nanohardness, Young’s modulus, elastic recovery, adhesion of coatings to substrates, friction constant, and surface roughness were measured.     

Characterization of native and anodic oxide films formed on commercial pure titanium using electrochemical properties and morphology techniques

Potentiostatically anodized oxide films on the surface of commercial pure titanium (cp-Ti) formed in sulfuric (0.5 M H₂SO₄) and in phosphoric (1.4 M H₃PO₄) acid solutions under variables anodizing voltages were investigated and compared with the native oxide film. Potentiodynamic polarization and electrochemical impedance spectroscopy, EIS, were used to predicate the different in corrosion behavior of the oxide film samples. Scanning electron microscope, SEM, and electron diffraction X-ray analysis, EDX, were used to investigate the difference in the morphology between different types of oxide films. The electrochemical characteristics were examined in phosphate saline buffer solution, PSB (pH 7.4) at 25 °C. Results have been shown that the nature of the native oxide film is thin and amorphous, while the process of anodization of Ti in both acid solutions plays an important role in changing the properties of passive oxide films. Significant increase in the corrosion resistance of the anodized surface film was recorded after 3 h of electrode immersion in PSB. On the other side, the coverage (θ) of film formed on cp-Ti was differed by changing the anodized acid solution. Impedance results showed that both the native film and anodized film formed on cp-Ti consist of two layers. The resistance of the anodized film has reached to the highest value by anodization of cp-Ti in H₃PO₄ and the inner layer in the anodized film formed in both acid solutions is also porous.     

Effect of potassium fluoride in electrolytic solution on the structure and properties of microarc oxidation coatings on magnesium alloy

Oxide coatings were produced on AM60B magnesium alloy substrate making use of microarc oxidation (MAO) technique. The effect of KF addition in the Na₂SiO₃-KOH electrolytic solution on the microarc oxidation process and the structure, composition, and properties of the oxide coatings was investigated. It was found that the addition of KF into the Na₂SiO₃-KOH electrolytic solution caused increase in the electrolyte conductivity and decrease in the work voltage and final voltage in the MAO process. Subsequently, the pore diameter and surface roughness of the microarc oxidation coating were decreased by the addition of KF, while the coating compactness was increased. At the same time, the phase compositions of the coatings also varied after the addition of KF in the electrolytic solution, owing to the participation of KF in the reaction and its incorporation into the oxide coating. Moreover, the coating formed in the electrolytic solution with KF had a higher surface hardness and better wear-resistance than that formed in the solution without KF, which was attributed to the changes in the spark discharge characteristics and the compositions and structures of the oxide coatings after the addition of KF.     

Structural characteristics and residual stresses in oxide films produced on Ti by pulsed unipolar plasma electrolytic oxidation

Oxide films, 7–10 µm thick, were produced on commercially pure titanium by plasma electrolytic oxidation in a sodium orthophosphate electrolyte using a pulsed unipolar current with frequency (f) and duty cycle (δ) varying within f = 0.1–10 kHz and δ = 0.8–0.2, respectively. The coatings comprised a mixture of an amorphous phase with nanocrystalline anatase and rutile phases, where the relative rutile content range was 17–25 wt%. Incorporation of phosphorus from the electrolyte into the coating in the form of PO₂ ^–, PO₃ ^2– and PO₄ ^3–, as demonstrated by EDX and FT-IR analyses, contributed to the formation of the amorphous phase. Residual stresses associated with the crystalline coating phase constituents were evaluated using the X-ray diffraction sin² ψ method. It was found that, depending on the treatment parameters, internal direct and shear stresses in anatase ranged from–205 (±17) to–431 (±27) MPa and from–98 (±6) to–145 (±10) MPa, respectively, whereas the rutile structure is comparatively stress-free.     

Surface characteristics of Zinc–TiO2 coatings prepared via micro-arc oxidation

Titanium (Ti) and its alloys are widely used as metallic biomaterials for fabrication of dental and orthopedic implants due to their favorable biocompatibility and corrosion resistance in a body environment. However, the thin oxide layer (TiO₂) on Ti substrate formed naturally in air or in many aqueous environments is bioinert and surrounded by fibrous tissues without producing any chemical or biological bond to bone when implanted. In the present work, Zinc-incorporated porous TiO₂ coatings (Zn–TiO₂) were prepared on Ti substrate by micro-arc oxidation (MAO) technique in the zinc gluconate-containing electrolyte. The surface morphology, cross-sectional morphology, composition, and phase of the coatings were analyzed using scanning electron microscopy, energy dispersive spectroscopy, and X-ray diffractometry, respectively. Surface topography and roughness of the coatings were investigated by atomic force microscopy operated in tapping mode. The results showed that Zn was successfully incorporated into the porous TiO₂ coatings, which did not alter apparently its surface topography and phase composition. In conclusion, the formation of porous Zn–TiO₂ coatings endow Ti with potential bioactivity and antibacterial activity, and we believe that the porous Zn–TiO₂ coatings on Ti by MAO technique might be promising candidates for orthopedic and dental implants     

Characterization of oxide coatings formed on tantalum by plasma electrolytic oxidation in 12-tungstosilicic acid

Oxide coatings were formed on tantalum by plasma electrolytic oxidation (PEO) process in 12-tungstosilicic acid. The PEO process can be divided into three stages with respect to change of the voltage-time response. The contribution of electron current density in total current density during anodization results in the transformation of the slope of voltage-time curve. The surface morphology, chemical and phase composition of oxide coatings were investigated by AFM, SEM-EDX, XRD and Raman spectroscopy. Oxide coating morphology is strongly dependent of PEO time. The elemental components of PEO coatings are Ta, O, Si and W. The oxide coatings are partly crystallized and mainly composed of WO₃, Ta₂O₅ and SiO₂. Raman spectroscopy showed that the outer layer of oxide coatings formed during the PEO process is silicate tungsten bronze.     

Effects of Poly(Propylene Oxide)–Poly(Ethylene Oxide)–Poly(Propylene Oxide) Triblock Copolymer on the Gelation of Poly(Ethylene Oxide)–Poly(Propylene Oxide)–Poly(Ethylene Oxide) Aqueous Solutions

Poly(ethylene oxide)-poly(propylene oxide)–poly(ethylene oxide) ((EO)_n–(PO)_m–(EO)_n) block copolymers, commercially available as Pluronics (BASF Corp.) and Poloxamers (ICI Corp.), have been widely applied in medicine, biochemistry, and other fields because of their ability to form reversible micelles and physical gels in aqueous solution. Generally, for PEO–PPO–PEO block copolymers with higher ethylene oxide concentration, the micellization and gelation in aqueous solution are easier. However, if we introduce the reverse block copolymer PPO–PEO–PPO into PEO–PPO–PEO aqueous solutions, the micellization and gelation of the system will be more complex. In this work, the reverse block copolymer PO₁₄–EO₂₄–PO₁₄ (17R4) was added to the Pluronics EO₂₀–PO₇₀–EO₂₀ (P123), EO₁₀₀–PO₆₅–EO₁₀₀ (F127), and EO₁₃₃–PO₅₀–EO₁₃₃ (F108) aqueous solutions with different molar ratios. The rheological properties of different mixtures were measured to study the additive effect on the gelation behavior. The sol–gel transition temperature of the P123, F127, and F108 solutions shifted to a higher temperature when 17R4 was added to the solutions. In addition, the existence of 17R4 greatly affected the stability of gels. These results help to better understand the gelation of Pluronic aqueous solutions.