Adherent octacalciumphosphate coating on titanium alloy using modulated electrochemical deposition method.

Our aims in this study were (1) to develop an electrochemical method of depositing adherent octacalciumphosphate (OCP) and other calcium phosphate coatings on titanium alloy (Ti6Al4V) substrates of different shapes and surface preparations, (2) to determine the properties of the coating (composition, morphology, thickness, dissolution), and (3) to observe transformation of OCP to carbonatehydroxyapatite (CHA) in simulated body fluid (SBF). Titanium (Ti)-alloy plates, tensile bars with four types of surfaces (grit-blasted with apatitic abrasive, chemically textured, arc-deposited, and Co-Cr-beaded) and dissolution cylinders were electrochemically coated with the use of modulated pulse time electric fields programmed with a custom-made dual microprocessor. Modulated electrochemical deposition (MECD) was carried out with pH and temperature conditions favorable for OCP formation. Coatings were characterized using X-ray diffraction, FT-IR, scanning electron microscopy, tensile strength tests, and solubility tests. XRD and FT-IR analyses showed that pure, uniform OCP coatings were produced on Ti6Al4V surfaces with coating-to-substrate tensile strengths greater than 7,000 psi. Coatings on Ti arc-deposited surfaces, chemically textured surfaces, and Co-Cr-beaded surfaces all gave tensile strengths ranging from 5,000 to 7,000 psi, with no coating shadows in the crevices. Dissolution of OCP coating in 100 mL of 0.1 M Tris buffer solution was determined from the amount of calcium (Ca) released onto the buffer, which was 7.7 +/- 1.0 ppm Ca at pH 7.3 after 4 h, and 22 -/+ 1.4 ppm Ca at pH 3 after 2 h. We found that OCP crystal size can be controlled by the current density and relative pulse time modulation. Our study demonstrated the following: (1) Highly adherent calcium phosphate (e.g., OCP) coating of uniform compositions (e.g., OCP) on Ti-alloy substrates can be obtained at low temperatures with the use of MECD by optimizing pulse time modulation of the electric field, reaction pH, temperature, and electrolyte composition; and (2) OCP readily transforms to CHA when exposed to SBF.