Tribological characterization of zirconia coatings deposited on Ti6Al4V components for orthopedic applications

One of the most important issues leading to the failure of total joint arthroplasty is related to the wear of the plastic components, which are generally made of ultra high molecular weight polyethylene (UHMWPE). Therefore, the reduction of joint wear represents one of the main challenges the resear...

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Veröffentlicht in:Materials Science & Engineering C 2016-05, Vol.62, p.643-655
Hauptverfasser: Berni, M., Lopomo, N., Marchiori, G., Gambardella, A., Boi, M., Bianchi, M., Visani, A., Pavan, P., Russo, A., Marcacci, M.
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container_issue
container_start_page 643
container_title Materials Science & Engineering C
container_volume 62
creator Berni, M.
Lopomo, N.
Marchiori, G.
Gambardella, A.
Boi, M.
Bianchi, M.
Visani, A.
Pavan, P.
Russo, A.
Marcacci, M.
description One of the most important issues leading to the failure of total joint arthroplasty is related to the wear of the plastic components, which are generally made of ultra high molecular weight polyethylene (UHMWPE). Therefore, the reduction of joint wear represents one of the main challenges the research in orthopedics is called to address nowadays. Surface treatments and coatings have been recognized as innovative methods to improve tribological properties, also in the orthopedic field. This work investigated the possibility to realize hard ceramic coatings on the metal component of a prosthesis, by means of Pulsed Plasma Deposition, in order to reduce friction and wear in the standard coupling against UHMWPE. Ti6Al4V substrates were coated with a 2μm thick yttria-stabilized zirconia (YSZ) layer. The mechanical properties of the YSZ coatings were assessed by nanoindentation tests performed on flat Ti6Al4V substrates. Tribological performance was evaluated using a ball-on-disk tribometer in dry and lubricated (i.e. with fetal bovine serum) highly-stressing conditions, up to an overall distance of 10km. Tribology was characterized in terms of coefficient of friction (CoF) and wear rate of the UHMWPE disk. After testing, specimens were analyzed through optical microscopy and SEM images, in order to check the wear degradation mechanisms. Progressive loading scratch tests were also performed in dry and wet conditions to determine the effects of the environment on the adhesion of the coating. Our results supported the beneficial effect of YSZ coating on metal components. In particular, the proposed solution significantly reduced UHMWPE wear rate and friction. At 10km of sliding distance, a wear rate reduction of about 18% in dry configuration and of 4% in presence of serum, was obtained by the coated group compared to the uncoated group. As far as friction in dry condition is concerned, the coating allowed to maintain low CoF values until the end of the tests, with an overall difference of about 40% compared to the uncoated balls. In wet conditions, the friction values were found to be comparable between coated and uncoated materials, mainly due to a premature delamination of the coating. Scratch tests in wet showed in fact a reduction of the critical load required to a complete delamination due to a formation of blister, although no change or damage occurred at the coating during the soaking period. Although conditions of high values of contact pressure were cons
doi_str_mv 10.1016/j.msec.2016.02.014
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Therefore, the reduction of joint wear represents one of the main challenges the research in orthopedics is called to address nowadays. Surface treatments and coatings have been recognized as innovative methods to improve tribological properties, also in the orthopedic field. This work investigated the possibility to realize hard ceramic coatings on the metal component of a prosthesis, by means of Pulsed Plasma Deposition, in order to reduce friction and wear in the standard coupling against UHMWPE. Ti6Al4V substrates were coated with a 2μm thick yttria-stabilized zirconia (YSZ) layer. The mechanical properties of the YSZ coatings were assessed by nanoindentation tests performed on flat Ti6Al4V substrates. Tribological performance was evaluated using a ball-on-disk tribometer in dry and lubricated (i.e. with fetal bovine serum) highly-stressing conditions, up to an overall distance of 10km. Tribology was characterized in terms of coefficient of friction (CoF) and wear rate of the UHMWPE disk. After testing, specimens were analyzed through optical microscopy and SEM images, in order to check the wear degradation mechanisms. Progressive loading scratch tests were also performed in dry and wet conditions to determine the effects of the environment on the adhesion of the coating. Our results supported the beneficial effect of YSZ coating on metal components. In particular, the proposed solution significantly reduced UHMWPE wear rate and friction. At 10km of sliding distance, a wear rate reduction of about 18% in dry configuration and of 4% in presence of serum, was obtained by the coated group compared to the uncoated group. As far as friction in dry condition is concerned, the coating allowed to maintain low CoF values until the end of the tests, with an overall difference of about 40% compared to the uncoated balls. In wet conditions, the friction values were found to be comparable between coated and uncoated materials, mainly due to a premature delamination of the coating. Scratch tests in wet showed in fact a reduction of the critical load required to a complete delamination due to a formation of blister, although no change or damage occurred at the coating during the soaking period. Although conditions of high values of contact pressure were considered, further analyses are however required to fully understand the behavior of YSZ coatings in wet environment and additional research on the deposition process will be mandatory in order to improve the coating tribological performance at long distances addressing orthopedic applications. •Yttria-stabilized zirconia ceramic coating were deposited on Ti6Al4V in order to reduce the wear of UHMWPE in joint replacement.•Provided coating method was Pulsed Plasma Deposition.•Realized materials were fully characterized by indentation, scratch and tribological tests.•Influence of the lubricant on the behavior of the coating was identified in terms of adhesion, wear rate and friction.•Obtained results supported a general beneficial effect of YSZ coating on metal components.</description><identifier>ISSN: 0928-4931</identifier><identifier>EISSN: 1873-0191</identifier><identifier>DOI: 10.1016/j.msec.2016.02.014</identifier><identifier>PMID: 26952468</identifier><language>eng</language><publisher>Netherlands: Elsevier B.V</publisher><subject>Animals ; Ball-on-disk ; Ceramic coating ; Coated Materials, Biocompatible - chemistry ; Coatings ; Drying ; Elastic Modulus ; Friction ; Friction coefficient ; Hardness ; Humans ; Materials Testing ; Microscopy, Electron, Scanning ; Orthopedics ; Polyethylenes ; Polyethylenes - chemistry ; Pulsed plasma deposition ; Titanium - chemistry ; Titanium alloy ; Titanium base alloys ; Tribology ; Ultra-high molecular weight polyethylene ; Wear ; Yttria stabilized zirconia ; Zirconium - chemistry</subject><ispartof>Materials Science &amp; Engineering C, 2016-05, Vol.62, p.643-655</ispartof><rights>2016 Elsevier B.V.</rights><rights>Copyright © 2016 Elsevier B.V. All rights reserved.</rights><woscitedreferencessubscribed>false</woscitedreferencessubscribed><citedby>FETCH-LOGICAL-c455t-22a7755690882cb09413e5b5f8955af6c9c94ab8ce251a310b6becd4d20967473</citedby><cites>FETCH-LOGICAL-c455t-22a7755690882cb09413e5b5f8955af6c9c94ab8ce251a310b6becd4d20967473</cites></display><links><openurl>$$Topenurl_article</openurl><openurlfulltext>$$Topenurlfull_article</openurlfulltext><thumbnail>$$Tsyndetics_thumb_exl</thumbnail><linktohtml>$$Uhttps://dx.doi.org/10.1016/j.msec.2016.02.014$$EHTML$$P50$$Gelsevier$$H</linktohtml><link.rule.ids>315,782,786,3554,27933,27934,46004</link.rule.ids><backlink>$$Uhttps://www.ncbi.nlm.nih.gov/pubmed/26952468$$D View this record in MEDLINE/PubMed$$Hfree_for_read</backlink></links><search><creatorcontrib>Berni, M.</creatorcontrib><creatorcontrib>Lopomo, N.</creatorcontrib><creatorcontrib>Marchiori, G.</creatorcontrib><creatorcontrib>Gambardella, A.</creatorcontrib><creatorcontrib>Boi, M.</creatorcontrib><creatorcontrib>Bianchi, M.</creatorcontrib><creatorcontrib>Visani, A.</creatorcontrib><creatorcontrib>Pavan, P.</creatorcontrib><creatorcontrib>Russo, A.</creatorcontrib><creatorcontrib>Marcacci, M.</creatorcontrib><title>Tribological characterization of zirconia coatings deposited on Ti6Al4V components for orthopedic applications</title><title>Materials Science &amp; Engineering C</title><addtitle>Mater Sci Eng C Mater Biol Appl</addtitle><description>One of the most important issues leading to the failure of total joint arthroplasty is related to the wear of the plastic components, which are generally made of ultra high molecular weight polyethylene (UHMWPE). Therefore, the reduction of joint wear represents one of the main challenges the research in orthopedics is called to address nowadays. Surface treatments and coatings have been recognized as innovative methods to improve tribological properties, also in the orthopedic field. This work investigated the possibility to realize hard ceramic coatings on the metal component of a prosthesis, by means of Pulsed Plasma Deposition, in order to reduce friction and wear in the standard coupling against UHMWPE. Ti6Al4V substrates were coated with a 2μm thick yttria-stabilized zirconia (YSZ) layer. The mechanical properties of the YSZ coatings were assessed by nanoindentation tests performed on flat Ti6Al4V substrates. Tribological performance was evaluated using a ball-on-disk tribometer in dry and lubricated (i.e. with fetal bovine serum) highly-stressing conditions, up to an overall distance of 10km. Tribology was characterized in terms of coefficient of friction (CoF) and wear rate of the UHMWPE disk. After testing, specimens were analyzed through optical microscopy and SEM images, in order to check the wear degradation mechanisms. Progressive loading scratch tests were also performed in dry and wet conditions to determine the effects of the environment on the adhesion of the coating. Our results supported the beneficial effect of YSZ coating on metal components. In particular, the proposed solution significantly reduced UHMWPE wear rate and friction. At 10km of sliding distance, a wear rate reduction of about 18% in dry configuration and of 4% in presence of serum, was obtained by the coated group compared to the uncoated group. As far as friction in dry condition is concerned, the coating allowed to maintain low CoF values until the end of the tests, with an overall difference of about 40% compared to the uncoated balls. In wet conditions, the friction values were found to be comparable between coated and uncoated materials, mainly due to a premature delamination of the coating. Scratch tests in wet showed in fact a reduction of the critical load required to a complete delamination due to a formation of blister, although no change or damage occurred at the coating during the soaking period. 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Therefore, the reduction of joint wear represents one of the main challenges the research in orthopedics is called to address nowadays. Surface treatments and coatings have been recognized as innovative methods to improve tribological properties, also in the orthopedic field. This work investigated the possibility to realize hard ceramic coatings on the metal component of a prosthesis, by means of Pulsed Plasma Deposition, in order to reduce friction and wear in the standard coupling against UHMWPE. Ti6Al4V substrates were coated with a 2μm thick yttria-stabilized zirconia (YSZ) layer. The mechanical properties of the YSZ coatings were assessed by nanoindentation tests performed on flat Ti6Al4V substrates. Tribological performance was evaluated using a ball-on-disk tribometer in dry and lubricated (i.e. with fetal bovine serum) highly-stressing conditions, up to an overall distance of 10km. Tribology was characterized in terms of coefficient of friction (CoF) and wear rate of the UHMWPE disk. After testing, specimens were analyzed through optical microscopy and SEM images, in order to check the wear degradation mechanisms. Progressive loading scratch tests were also performed in dry and wet conditions to determine the effects of the environment on the adhesion of the coating. Our results supported the beneficial effect of YSZ coating on metal components. In particular, the proposed solution significantly reduced UHMWPE wear rate and friction. At 10km of sliding distance, a wear rate reduction of about 18% in dry configuration and of 4% in presence of serum, was obtained by the coated group compared to the uncoated group. As far as friction in dry condition is concerned, the coating allowed to maintain low CoF values until the end of the tests, with an overall difference of about 40% compared to the uncoated balls. In wet conditions, the friction values were found to be comparable between coated and uncoated materials, mainly due to a premature delamination of the coating. Scratch tests in wet showed in fact a reduction of the critical load required to a complete delamination due to a formation of blister, although no change or damage occurred at the coating during the soaking period. Although conditions of high values of contact pressure were considered, further analyses are however required to fully understand the behavior of YSZ coatings in wet environment and additional research on the deposition process will be mandatory in order to improve the coating tribological performance at long distances addressing orthopedic applications. •Yttria-stabilized zirconia ceramic coating were deposited on Ti6Al4V in order to reduce the wear of UHMWPE in joint replacement.•Provided coating method was Pulsed Plasma Deposition.•Realized materials were fully characterized by indentation, scratch and tribological tests.•Influence of the lubricant on the behavior of the coating was identified in terms of adhesion, wear rate and friction.•Obtained results supported a general beneficial effect of YSZ coating on metal components.</abstract><cop>Netherlands</cop><pub>Elsevier B.V</pub><pmid>26952468</pmid><doi>10.1016/j.msec.2016.02.014</doi><tpages>13</tpages></addata></record>
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subjects Animals
Ball-on-disk
Ceramic coating
Coated Materials, Biocompatible - chemistry
Coatings
Drying
Elastic Modulus
Friction
Friction coefficient
Hardness
Humans
Materials Testing
Microscopy, Electron, Scanning
Orthopedics
Polyethylenes
Polyethylenes - chemistry
Pulsed plasma deposition
Titanium - chemistry
Titanium alloy
Titanium base alloys
Tribology
Ultra-high molecular weight polyethylene
Wear
Yttria stabilized zirconia
Zirconium - chemistry
title Tribological characterization of zirconia coatings deposited on Ti6Al4V components for orthopedic applications
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