Effect of particle size on molten states of starting powder and degradation of the relevant plasma-sprayed hydroxyapatite coatings

Crystallinity of hydroxyapatite (HA) coatings is an important parameter to evaluate their stability. Variation of the size distribution of the starting powder is one way to alter crystallinity of coatings. The fundamental reason might be the variation of molten states of HA powders with different particle sizes. In the experiments, HA particles sized between 1 and 180 μm were divided into six groups by sieving. It was observed that the trend of crystallinity of coatings on particle size is not linear but fluctuates. The fluctuation of crystallinity was caused by the alteration of molten states of HA powders with different size distributions. It is concluded that the molten state of starting powder also fluctuated with particle size but the trend was different from that of crystallinity. Coatings sprayed with different particle sizes were immersed in deionized water for 1 month. After immersion, severe degradation and break-up were observed on the surface of coatings with the highest crystallinity, which were sprayed with large sized HA powders. It may be the high porosities in these coatings that cause the severe degradation. This shows that high crystallinity is not necessarily related to high stability of coatings and microstructure is of great importance when stability of coatings is considered.