Sonoelectrochemical deposition of calcium phosphates on carbon materials: effect of current density.

Calcium phosphate (CaP) coatings on carbon fabric substrate were produced by sonoelectrodeposition at different current densities (5, 8, 13, 20 and 34 mA/cm2). The surface morphology and chemical composition of the coatings were characterized by SEM, Raman and FTIR spectra. The results showed that at 5 mA/cm2 current density, the coating exhibits plate-like morphology, indicating an octacalcium phosphate (OCP) phase was pre-formed in the deposits and then converted into hydroxyapatite (HA). When the current density was increased to 8 mA/cm2 and higher, the coatings exhibited needle-like morphology corresponding to a HA phase. Furthermore, the sonoelectrodeposited CaP coating exhibited denser and more uniform structures with smaller crystal sizes as the current density increased. Cathodic reaction mechanisms of CaP coatings on carbon in the sonoelectrochemical processes are proposed to explain the different kinds of calcium phosphate obtained.