Development of hydroxyapatite coatings by solution precursor plasma spray process and their microstructural characterization

Solution precursor plasma spraying (SPPS) is a promising method of obtaining coatings with unique microstructural features. The present study reports about the development of hydroxyapatite (HA) coatings by SPPS using water-based calcium-phosphate solution and about the analyses of their microstructure. X-ray diffraction (XRD) analysis showed that HA was the major crystal phase of the coatings, being present in the range from 95% to 98%. The coatings of greater HA content were obtained while spraying using shorter spray distance. The coating crystallinity ranges from 24% to 69% depending on the temperature at deposition. An increase of the temperature results in greater crystallinity. The obtained coatings' microstructures may be described by dome-like surface and by the columnar-like cross-section when using precursor with low concentration. The use of concentrated solution precursor results in cauliflower-like structures composed of agglomerated fragmented shells and fine spherical particles. The possible phenomena occurring in droplets in contact with the plasma jet and the coating build-up mechanisms were tentatively explained. •Hydroxyapatite coatings were synthesized by solution precursor plasma spraying using two precursor concentrations.•Dome-like and cauliflower-like surface morphologies were achieved.•Solution concentration significantly affects the microstructure of the coatings.•Coating purity and crystallinity were greatly influenced by spray distance and solution injection rate.