Highly crystalline MP-1 hydroxylapatite coating. Part I: In vitro characterization and comparison to other plasma-sprayed hydroxylapatite coatings.

A novel pressurized hydrothermal post-plasma-spray process, referred to as MP-1, has been developed to convert the crystalline non-HA and amorphous components of plasma-sprayed hydroxylapatite coating back into crystalline HA. No detrimental effects are observed on the strength of either the base metal or the coating. X-ray diffraction (XRD) and FTIR analysis, surface roughness, shear adhesion strength and calcium solubility testing were conducted on Calcitite coated samples before and after treatment with this process. Other commercially available coatings were also studied using XRD and solubility testing. Quantitative XRD data show that the MP-1 treatment increases the average crystalline HA content of the Calcitite coating from 77% to 96%, while the amorphous content decreases from 21% to 4%. Other commercially available dental implant coatings ranged in crystalline HA content from 45% to 73%, with amorphous phase content ranging from 29% to 62%. FTIR spectra for treated coatings were significantly more well defined, and showed an increase in peak separation and intensity. Surface roughness and shear adhesion strength were not affected by the treatment. In vitro solubility testing revealed that for all coatings there is an initial introduction of calcium into solution over the first 2 h of testing; however, the amount of calcium dissolved was significantly lower for the MP-1 coating. Under a pH and temperature representative of normal physiologic conditions, the rate of calcium dissolution for the MP-1 coating was significantly lower than that of the other commercial HA coatings. In increasingly acidic conditions, the MP-1 coating was compared to the Calcitite coating and was found to have a significantly slower rate of calcium release. The MP-1 treatment enhances typical HA coatings by increasing the crystalline HA content at the expense of the plasma-spray-induced soluble phases without a reduction in the strength of the coating. The resulting coatings exhibit significantly decreased in vitro solubility over a wide range of pH. The results of this solubility testing suggest that the treated coating may show significantly enhanced in vivo stability, even under the extreme conditions encountered during periods of infection or rigorous detoxification procedures. The significant differences between plasma-sprayed HA coatings reported here underscore the need for industry and academic researchers to raise the level of discourse and understanding of HA coatings. By offering consistent and accurate descriptions of coating compositions and methods of analysis, meaningful comparisons between different HA coatings can be made.