Microstructural characterization of plasma-sprayed hydroxyapatite–10 wt% ZrO2 composite coating on titanium

Previous research showed that the concept of adding ZrO2 as second phase to hydroxyapatite (HA) significantly increased the bonding strength of plasma-sprayed composite material. The present work aimed to investigate the microstructural characteristics of plasma-sprayed hydroxyapatite–10 wt% ZrO2 composite coating on titanium using X-ray diffractometry (XRD) and transmission electron microscopy (TEM). In TEM, phases such as HA, amorphous calcium phosphate, α-TCP, ZrO2 and minor transformed CaZrO3 are identified. The cubic phase of ZrO2 in HA–10 wt% ZrO2 powders before coating maintains during plasma spraying, and zirconia particle apparently bonds well to the calcium phosphate matrix with local crystallographic relationship. The transformed CaZrO3 does not exist as interface interphase between calcium phosphate matrix and zirconia particle. Instead, reaction of calcium phosphate and zirconia occurs rapidly to transform ZrO2 into CaZrO3. The toughening mechanism of the material studied and its biological implication of the system are discussed.