Architectural design of diamond-like carbon coatings for long-lasting joint replacements

Surface engineering through the application of super-hard, low-friction coatings as a potential approach for increasing the durability of metal-on-metal replacements is attracting significant attention. In this study innovative design strategies are proposed for the development of diamond-like-carbon (DLC) coatings against the damage caused by wear particles on the joint replacements. Finite element modeling is used to analyze stress distributions induced by wear particles of different sizes in the newly-designed coating in comparison to its conventional monolithic counterpart. The critical roles of architectural design in regulating stress concentrations and suppressing crack initiation within the coatings is elucidated. Notably, the introduction of multilayer structure with graded modulus is effective in modifying the stress field and reducing the magnitude and size of stress concentrations in the DLC diamond-like-carbon coatings. The new design is expected to greatly improve the load-carrying ability of surface coatings on prosthetic implants, in addition to the provision of damage tolerance through crack arrest.