M. Kot

Parylene coatings on stainless steel 316L surface for medical applications — Mechanical and protective properties

The mechanical and protective properties of parylene N and C coatings (2-20 μm) on stainless steel 316L implant materials were investigated. The coatings were characterized by scanning electron and confocal microscopes, microindentation and scratch tests, whereas their protective properties were evaluated in terms of quenching metal ion release from stainless steel to simulated body fluid (Hanks solution). The obtained results revealed that for parylene C coatings, the critical load for initial cracks is 3-5 times higher and the total metal ions release is reduced 3 times more efficiently compared to parylene N. It was thus concluded that parylene C exhibits superior mechanical and protective properties for application as a micrometer coating material for stainless steel implants.

Influence of polyetheretherketone coatings on the Ti–13Nb–13Zr titanium alloy's bio-tribological properties and corrosion resistance

Polyetheretherketone (PEEK) coatings of 70-90μm thick were electrophoretically deposited from a suspension of PEEK powder in ethanol on near-β Ti-13Nb-13Zr titanium alloy. In order to produce good quality coatings, the composition of the suspension (pH) and optimized deposition parameters (applied voltage and time) were experimentally selected. The as-deposited coatings exhibited the uniform distribution of PEEK powders on the substrate. The subsequent annealing at a temperature above the PEEK melting point enabled homogeneous, semi-crystalline coatings with spherulitic morphology to be produced. A micro-scratch test showed that the coatings exhibited very good adhesion to the titanium alloy substrate. Coating delamination was not observed even up to a maximal load of 30N. The PEEK coatings significantly improved the tribological properties of the Ti-13Nb-13Zr alloy. The coefficient of friction was reduced from 0.55 for an uncoated alloy to 0.40 and 0.12 for a coated alloy in a dry sliding and sliding in Ringers solution, respectively. The PEEK coatings exhibited excellent wear resistance in both contact conditions. Their wear rate was more than 200 times smaller compared with the wear rate of the uncoated Ti-13Nb-13Zr alloy. The obtained results indicate that electrophoretically deposited PEEK coatings on the near-β titanium alloy exhibit very useful properties for their prospective tribological applications in medicine.

Electrophoretic deposition and characterization of HA/chitosan nanocomposite coatings on Ti6Al7Nb alloy

Nano-hydroxyapatite/chitosan (nc-HA/chitosan) composite coatings were produced on two phase (α+β) Ti6Al7Nb titanium alloy substrates by electrophoretic deposition (EPD). The microstructure of the coatings was examined by scanning- and transmission electron microscopy methods as well as by X-ray diffractometry. The coatings, 770 nm–800 nm thick, were uniform, without any cracks or presence of large voids and they exhibited good adhesion to the titanium alloy substrate. The microstructure of the coatings consisted of nc-HA needle-like particles homogeneously embedded in a chitosan matrix. The deposited coatings exhibited good adhesion to the substrate. The best adhesion to the titanium alloy was determined for the coating deposited from suspensions containing 4 g/L of HA at 10 V during 240 s. The results confirm EPD as a convenient method to develop uniform and crack-free nanoscale organic-inorganic composite coatings on two phase titanium alloy substrates with potential application in orthopedic and dental implants.

Development and complex characterization of bio-tribological Cr/CrN + a-C:H (doped Cr) nano-multilayer protective coatings for carbon–fiber-composite materials

Carbon fiber structures provide strength, stiffness, and fatigue resistance. Carbon-based materials show, however, significant oxidative degradation in air beginning at temperatures in the region of 400 °C. Therefore, a coating concept for carbon–carbon composites consists of an inner part, which serves as a structural link with stress compensation ability to the carbon substrate, and an outer part, which acts as a diffusion barrier. In the presented paper, chromium/chromium nitride (Cr/CrN) multilayer structure has been selected as the inner part. The outer part of the coating, in the presented paper, was hydrogenated amorphous carbon (a-C:H). Among doping metals, Cr, as one of the carbide formed elements, possesses an attractive combination of properties (corrosion resistance, wear resistance, etc.). Thus, in the presented paper, a-C:H part of the coating was implanted by Cr nanocrystals. Coatings were deposited by means of magnetron sputtering technique. They were subjected to complex investigations. Mechanisms of a mechanical wear of analyzed systems were presented, focusing on the cracking propagation in ball-on-disc tests using a 1 N and 5 N applied loads for 20 000 cycles. Complex microstructure analysis of presented nano-multilayer coatings, before and after mechanical tests, were performed by means of transmission electron microscopy (TEM). The microstructure characterization revealed that cracking, which was propagating in the outer part of the coating (in the carbon part) in the layer with lower nano-particle content, was stopped at the interface with the higher nano-particle content layer. In the case of the inner part of the coating (Cr/Cr2N), ceramic layers showed brittle cracking, while metallic (Cr) ones deformed plastically.

Micromechanical and Tribological Properties of Nanocomposite nc-TiC/a-C Coatings

The nanocomposite coatings composed of nanocrystalline TiC grains embedded in hydrogen free amorphous carbon a-C matrix (nc-TiC/a-C) were deposited by magnetron sputtering on the two substrates, oxygen hardened Ti-6Al-4V alloy and heat treated VANADIS 23 steel. The Ti-6Al-4V alloy was oxygen hardened by plasma glow discharge. Micro-mechanical and tribological properties as well as coating adhesion to the substrates were investigated. Micro/nanostructure of the coatings and the substrates were examined using scanning- and transmission electron microscopy methods as well as X-ray diffractometry. Nano-, microhardness tests performed for the coated materials showed average hardness 13.4-14.7 GPa and modulus of elasticity 160 GPa. Scratch test revealed good adhesion of coatings to the both substrates. The nanocomposite coatings significantly improved tribological properties of the titanium alloy and steel, increased wear resistance and decreased friction coefficient.

Effect of Surface Roughness and Structure Features on Tribological Properties of Electrodeposited Nanocrystalline Ni and Ni/Al2O3 Coatings

Metal matrix composite coatings obtained by electrodeposition are one of the ways of improving the surfaces of materials to enhance their durability and properties required in different applications. This paper presents an analysis of the surface topography, microstructure and properties (residual stresses, microhardness, wear resistance) of Ni/Al2O3 nanocomposite coatings electrodeposited on steel substrates from modified Watt’s-type baths containing various concentrations of Al2O3 nanoparticles and a saccharin additive. The residual stresses measured in the Ni/Al2O3 coatings decreased with an increasing amount of the co-deposited ceramics. It was established that the addition of Al2O3 powder significantly improved the coatings’ microhardness. The wear mechanism changed from adhesive-abrasive to abrasive with a rising amount of Al2O3 particles and coating microhardness. Nanocomposite coatings also exhibited a lower coefficient of friction than that of a pure Ni-electrodeposited coating. The friction was found to depend on the surface roughness, and the smoother surfaces gave lower friction coefficients.

Microstructure characterization of advanced protective Cr/CrN+a‐C:H/a‐C:H:Cr multilayer coatings on carbon fibre composite (CFC)

Studies of advanced protective chromium‐based coatings on the carbon fibre composite (CFC) were performed. Multidisciplinary examinations were carried out comprising: microstructure transmission electron microscopy (TEM, HREM) studies, micromechanical analysis and wear resistance. Coatings were prepared using a magnetron sputtering technique with application of high‐purity chromium and carbon (graphite) targets deposited on the CFC substrate. Selection of the CFC for surface modification in respect to irregularities on the surface making the CFC surface more smooth was performed. Deposited coatings consisted of two parts. The inner part was responsible for the residual stress compensation and cracking initiation as well as resistance at elevated temperatures occurring namely during surgical tools sterilization process. The outer part was responsible for wear resistance properties and biocompatibility. Experimental studies revealed that irregularities on the substrate surface had a negative influence on the crystallites growth direction. Chromium implanted into the a‐C:H structure reacted with carbon forming the cubic nanocrystal chromium carbides of the Cr23C6 type. The cracking was initiated at the coating/substrate interface and the energy of brittle cracking was reduced because of the plastic deformation at each Cr interlayer interface. The wear mechanism and cracking process was described in micro‐ and nanoscale by means of transmission electron microscope studies. Examined materials of coated CFC type would find applications in advanced surgical tools.

In vitro hemocompatibility on thin ceramic and hydrogel films deposited on polymer substrate performed in arterial flow conditions.

Hydrogel coatings were stabilized by titanium carbonitride a-C:H:Ti:N buffer layers deposited directly onto the polyurethane (PU) substrate beneath a final hydrogel coating. Coatings of a-C:H:Ti:N were deposited using a hybrid method of pulsed laser deposition (PLD) and magnetron sputtering (MS) under high vacuum conditions. The influence of the buffer a-C:H:Ti:N layer on the hydrogel coating was analysed by means of a multi-scale microstructure study. Mechanical tests were performed at an indentation load of 5 mN using Berkovich indenter geometry. Haemocompatible analyses were performed in vitro using a blood flow simulator. The blood-material interaction was analysed under dynamic conditions. The coating fabrication procedure improved the coating stability due to the deposition of the amorphous titanium carbonitride buffer layer.

Mechanical and tribological properties of carbon-based graded coatings

The paper presents research on coatings with advanced architecture, composed of a Cr/Cr2N ceramic/metal multilayer and graded carbon layers with varying properties fromCr/a-C:H to a-C:N. The microstructure of the coatings was analysed using transmission electron microscopy and Energy Dispersive Spectroscopy, the mechanical properties were tested by nanoindentation, spherical indentation, and scratch testing, and tribological tests were also conducted. The proper selection of subsequent layers in graded coatings allowed high hardness and fracture resistance to be obtained as well as good adhesion to multilayers. Moreover, these coatings have higher wear resistance than single coatings and a friction coefficient equal to 0.25.

Effect of Interfaces on Mechanical Properties of Ceramic/Metal Multilayers

Multilayers of alternate Ti/TiN coatings deposited on X20Cr13 ferritic stainless steel by pulsed laser deposition (PLD) method have been tested using instrumented indentation. The effect of bilayer period and metal/ceramic thickness ratio were studied.