Design of experiment analysis of the Sulzer Metco DJ high velocity oxy-fuel coating of hydroxyapatite for orthopedic applications

Journal of Thermal Spray Technology

Volumn 20, Issue 1-2, 2011, Pages 186-194

  Hasan, S ^a   Stokes, J ^a  

^a DUBLIN CITY UNIVERSITY   (Ireland)

Author keywords

design of experiments; femoral implants; HVOF; hydroxyapatite; plasma spray

Indexed keywords

AIR FLOW-RATE; ATMOSPHERIC PLASMAS; CRYSTALLINITIES; FEMORAL IMPLANTS; HA COATING; HIGH CRYSTALLINITY; HIGH VELOCITY OXY-FUEL; HVOF; HVOF PROCESS; NEW VENTURES; ORTHOPEDIC APPLICATIONS; OXYGEN FLOW RATES; PLASMA SPRAY; PLASMA SPRAY TECHNIQUES; POWDER FEED RATE; POWDER FLOW RATE; SPRAY DISTANCES; SPRAYING PROCESS; SULZER METCO; THERMAL SPRAY;

AIR; APATITE; CERAMIC MATERIALS; HVOF THERMAL SPRAYING; HYDROXYAPATITE; MECHANICAL PROPERTIES; OPTIMIZATION; OXYGEN; PLASMA DEPOSITION; PLASMA JETS; PLASMA SPRAYING; PLASMAS; PROPYLENE; PROTECTIVE COATINGS; RESEARCH; SPRAYED COATINGS; THERMAL SPRAYING;

DESIGN OF EXPERIMENTS;

EID: 78650716105     PISSN: 10599630     EISSN: None     Source Type: Journal    
DOI: 10.1007/s11666-010-9566-0     Document Type: Conference Paper

References (38)

1. J Stokes L Looney 2004 Residual Stress in HVOF Thermally Sprayed Thick Deposits J. Surf. Coat. Technol. 177-178 18 23 1:CAS:528:DC%2BD2cXhtVOqu7o%3D 10.1016/j.surfcoat.2003.06.003 (Pubitemid 38241948)
2. T.J. Levingstone, "Optimisation of Plasma Sprayed Hydroxyapatite Coatings," Ph.D. thesis, Dublin City University, Ireland, 2008, http://doras.dcu.ie/579/
3. P Fauchais 2004 Understanding Plasma Spraying J. Phys. D Appl. Phys. 37 R86 1:CAS:528:DC%2BD2cXktFemt7s%3D 10.1088/0022-3727/37/9/R02
4. HC Gledhill IG Turner C Doyle 2001 In Vitro Dissolution Behaviour of Two Morphologically Different Thermally Sprayed Hydroxyapatite Coatings Biomaterials 22 695 700 1:CAS:528:DC%2BD3MXhtFaksLs%3D 10.1016/S0142-9612(00)00232-5 (Pubitemid 32112294)
5. HC Gledhill IG Turner C Doyle 2001 In Vitro Fatigue Behaviour of Vacuum Plasma, Detonation Gun Sprayed Hydroxyapatite Coatings Biomaterials 22 1233 1240 1:CAS:528:DC%2BD3MXjtleqtbo%3D 10.1016/S0142-9612(00)00273-8 (Pubitemid 32409944)
6. HC Gledhill IG Turner C Doyle 1999 Direct Morphological Comparison of Vacuum Plasma Sprayed, Detonation Gun Sprayed Hydroxyapatite Coatings for Orthopaedic Applications Biomaterials 20 315 322 1:CAS:528:DyaK1MXht12ntrk%3D 10.1016/S0142-9612(98)00166-5 (Pubitemid 29054693)
7. T.J. Levingstone, Ceramics for Medical Applications, Dublin City University, Ireland, 2008, ISBN: 1-87232-752-4
8. S.J. Schneider, Jr., Ceramics and Glasses, Vol 4, ASM International, Ohio, USA, 1991, ISBN 13: 978-0-87170-282-1
9. P Ducheyne J Beight J Cuckler B Evans S Radin 1990 Effect of Calcium Phosphate Coating Characteristics on Early Post-Operative Bone Tissue Ingrowth Biomaterials 11 531 540 1:CAS:528:DyaK3MXovVGqsQ%3D%3D 10.1016/0142-9612(90) 90073-Y (Pubitemid 20367827)
10. K. Soballe, The role of H-A-C in ingrowth prostheses, Hydroxyapatite Ceramic, a Decade of Experience in Hip Arthroplasty, the Proceedings of a Two Day Symposium, R. Furlong, Ed., Held at the Royal College of Surgeons of England on Thursday 2nd & Friday 3rd November 1995, Furlong Research Foundation, London, 1996, p 57-67
11. ASTM F1185-03, Standard Specification for Composition of Ceramic Hydroxyapatite for Surgical Implants, ASTM F1185-03, ASTM International, 2003
12. KA Gross K Heeman KS Saber-Samandari 2010 Evaluation of Commercial Implants with Nanoindentation Defines Future Development Needs for Hydroxyapatite Coatings J. Biomed. Mater. Res.: Appl. Biomater. 93B 1 1 8 1:CAS:528:DC%2BC3cXivFarsbw%3D 10.1002/jbm.b.31537
13. Anonymous, Implants for Surgery-Hydroxyapatite. Part 2: Coatings of Hydroxyapatite, BS ISO 13779-2:2000, 2000
14. YC Tsui C Doyle TW Clyne 1998 Plasma Sprayed Hydroxyapatite Coatings on Titanium Substrates Part 2: Optimisation of Coating Properties Biomaterials 19 11 2031 2043 1:CAS:528:DyaK1cXotVSgtr8%3D 10.1016/S0142-9612(98)00104-5 (Pubitemid 28539848)
15. L Sun CC Berndt CP Grey 2003 Phase, Structural, Microstructural Investigations of Plasma Sprayed Hydroxyapatite Coatings Mater. Sci. Eng. A 360 11/15 70 84
16. MF Morks A Kobayashi 2007 Effect of Gun Current on the Microstructure, Crystallinity of Plasma Sprayed Hydroxyapatite Coatings Appl. Surf. Sci. 253 17 7136 7142 1:CAS:528:DC%2BD2sXlslGjsrc%3D 10.1016/j.apsusc.2007.02.183 (Pubitemid 46783126)
17. M.P. Taylor, "Assessment of Plasma-Sprayed Hydroxyapatite Coatings," Ph.D. thesis, University of Birmingham, Birmingham, 1994
18. P Cheang KA Khor 1995 Thermal Spraying of Hydroxyapatite (HA) Coatings: Effects of Powder Feedstock J. Mater. Process. Technol. 48 429 436 10.1016/0924-0136(94)01679-U
19. CH Quek KA Khor P Cheang 1999 Influence of Processing Parameters in the Plasma Spraying of Hydroxyapatite/Ti-6Al-4V Composite Coatings J. Mater. Process. Technol. 89-90 550 555 10.1016/S0924-0136(99)00062-X
20. YP Lu ST Li RF Zhu MS Li 2002 Further Studies on the Effect of Stand-off Distance on Characteristics of Plasma Sprayed Hydroxyapatite Coating Surf. Coat. Technol. 157 221 225 1:CAS:528:DC%2BD38XkvFChtrY%3D
21. JF Li H Liao B Normand C Cordier G Maurin J Foct C Coddet 2003 Uniform Design Method for Optimization of Process Parameters of Plasma Sprayed TiN Coatings Surf. Coat. Technol. 176 1 13 1:CAS:528:DC%2BD3sXot1Omsrg%3D 10.1016/S0257-8972(03)00019-7 (Pubitemid 37388057)
22. T.J. Steeper, D.J. Varacalle, Jr., G.C. Wilson, W.L. Riggs, A.J. Rotolico, and J.E. Nerz, A Design of Experiment Study of Plasma Sprayed Alumina-Titania Coatings, Thermal Spray: International Advances in Coatings Technology, 13th International Thermal Spray Conference, C.C. Berndt, Ed., 28th May-5th June, 1999i Orlando, FL, 1992
23. T.J. Steeper, D.J. Varacalle, Jr., G.C. Wilson, W.L. Riggs, A.J. Rotolico, and J.E. Nerz, Optimizing Plasma Spraying Alumina-Titania Coatings Using Statistical Methods, Thermal Spray Coatings: Research, Design and Applications, 5th National Thermal Spray Conference, C.C. Berndt and T.F. Bernecki, Ed., June 7-11, 1993, Anaheim, CA, 1993
24. JR Mawdsley YJ Su KT Faber TF Bernecki 2001 Optimization of Small-Particle Plasma-Sprayed Alumina Coatings Using Designed Experiments Mater. Sci. Eng. A 308 189 199 10.1016/S0921-5093(00)01992-4 (Pubitemid 32464300)
25. T.J. Steeper, D.J. Varacalle, Jr., G.C. Wilson, W.L. Riggs, A.J. Rotolico, and J.E. Nerz, A Taguchi Design of Experiment Study of Plasma Sprayed Alumina Coatings, Thermal Spray Coatings: Research, Design and Applications, 1993
26. D.F. Gibbons and K.A. Buran, Microscopic Analysis of Retrieved Polymethylmethacrylate (PMMA) Bone Cement, Implant Retrieval: Material and Biological Analysis, National Bureau of Standards Special Publication 601, National Bureau of Standards, Washington, DC, 1981
27. B Lin M Jean J Chou 2007 Using Response Surface Methodology for Optimizing Deposited Partially Stabilized Zirconia in Plasma Spraying Appl. Surf. Sci. 253 6 3254 3262 1:CAS:528:DC%2BD2sXkvVOr 10.1016/j.apsusc.2006.07.021 (Pubitemid 46014354)
28. J Cizek KA Khor Z Prochazka 2007 Influence of Spraying Conditions on Thermal and Velocity Properties of Plasma Sprayed Hydroxyapatite Mater. Sci. Eng. C 27 2 340 344 1:CAS:528:DC%2BD2sXhsF2isLY%3D 10.1016/j.msec.2006.05.002 (Pubitemid 46205307)
29. S Dyshlovenko C Pierlot L Pawlowski R Tomaszek P Chagnon 2006 Experimental Design of Plasma Spraying and Laser Treatment of Hydroxyapatite Coatings Surf. Coat. Technol. 201 2054 2060 1:CAS:528:DC%2BD28XpslSnu7k%3D 10.1016/j.surfcoat.2006.04.055 (Pubitemid 44341059)
30. S Dyshlovenko L Pawlowski P Roussel D Murano A Le Maguer 2006 Relationship Between Plasma Spray Operational Parameters and Microstructure of Hydroxyapatite Coatings and Powder Particles Sprayed into Water Surf. Coat. Technol. 200 12-13 3845 3855 1:CAS:528:DC%2BD28Xhs1yqsL0%3D 10.1016/j.surfcoat. 2004.11.037 (Pubitemid 43246064)
31. J. Stokes, Theory and Application of Sulzer Metco High Velocity Oxy-Fuel (HVOF) Thermal Spray Process, © Dublin City University, 2008, ISBN 1-87232-753 ISSN 1649-8232
32. SWK Kweh KA Khor P Cheang 2000 Plasma-Sprayed Hydroxyapatite (HA) Coatings with Flame-Spheroidized Feedstock: Microstructure and Mechanical Properties Biomaterials 21 1223 1234 1:CAS:528:DC%2BD3cXjtF2jt7k%3D 10.1016/S0142-9612(99)00275-6 (Pubitemid 30195720)
33. J Stokes L Looney 2001 HVOF System Definition to Maximise the Thickness of Formed Components J. Surf. Coat. Technol. 148 1 18 24 1:CAS:528: DC%2BD3MXnsleltbs%3D 10.1016/S0257-8972(01)01272-5 (Pubitemid 34025703)
34. F.W. Munjone and G. Irons, The Evolution of Thermal Spray Automation, Proceedings of the 5th National Thermal Spraying Conference, Anaheim, CA, USA, 1993, p 263-273
35. G. Irons, Thermal Spray Applications Speeds, Proceedings of the 14th International Thermal Spray Conference, Kobe, Japan, 1995, p 1165-1168
36. KA Gross CC Berndt VJ Iacono 1998 Variability of Hydroxyapatite Coated Dental Implants Int. J. Oral Maxillofac. Implants 13 601 610 1:STN:280:DyaK1M%2Fht1agtw%3D%3D
37. KA Gross CC Berndt H Herman 1998 Formation of the Amorphous Phase in Hydroxyapatite Coatings J. Biomed. Mater. Res. 39 407 414 1:CAS:528: DyaK1cXnsVOksA%3D%3D 10.1002/(SICI)1097-4636(19980305)39:3<407::AID- JBM9>3.0.CO;2-N (Pubitemid 28063456)
38. BS ISO13779, Implants for Surgery-Hydroxyapatite. Part 1: Ceramic Hydroxyapatite, BS ISO 13779-1:2000, International Organisation for Standards, USA, 2000