Review articleRF-magnetron sputter deposited hydroxyapatite-based composite & multilayer coatings: A systematic review from mechanical, corrosion, and biological points of view
Introduction
The family of calcium phosphate (CaP) materials, mainly including hydroxyapatite (HAp) and tricalcium phosphates (α and β-TCP) have been extensively employed in bio-related applications, particularly thanks to their high biocompatibility and bioactivity [[1], [2], [3], [4], [5], [6], [7], [8], [9], [10], [11]].
Hydroxyapatite (Ca10(PO4)6OH2) with Ca/P ratio of 1.67, possesses the most similar chemical composition to the human bone. It was believed that HAp can be a promising material to fabricate both bulk ceramics implant and/or thin film bioactive coating [[12], [13], [14], [15], [16], [17]]. However, the applications of HAp in the bulk form has been greatly restricted owing to its brittle nature. On the other hand, the HAp-coated metallic implants have received increasing attention, and progressively developed since they simultaneously take the advantageous of metallic implant strength and bioactivity of HAp [[18], [19], [20], [21], [22]].
To date, a wide spectrum of practical techniques including electrochemical deposition [20,[23], [24], [25], [26], [27], [28], [29]], biomimetic deposition [30], sol-gel [31,32], plasma-spraying [33], RF magnetron sputtering [[34], [35], [36], [37], [38], [39], [40]], micro-arc oxidation [[41], [42], [43]], pulsed laser deposition [44,45], and etc. have been developed to prepare biocompatible and bioactive coatings, particularly HAp on the surface of implants. However, the RF magnetron sputtering bears several advantageous such as high efficiency, great control over uniformity and thickness of the film, strong adherence of film to the substrate, fabrication of dense and compact films, possibility to work at low temperatures, deposition of insulating films, possibility to deposit films on the heat-sensitive implants, and automatization ability over the others [[46], [47], [48], [49], [50]]. The flaws and drawbacks of this method majorly includes high cost, low deposition rate, and being line-of-sight technique that should be also taken into account. As a general note, before industrialization of a given technique in bio-related applications, there is a requirement for in-depth R&D to evaluate its pros and cons [[51], [52], [53], [54], [55]].
In spite of the fact that the overall characteristics of pure HAp coatings have been studied for more than several decades, the clinical use of theses coatings has not been as much addressed. The main reasons are connected with the insufficient knowledge on the in vivo behavior of these coatings after implantation procedure [56,57].
Recently, the attempts have been made to use HAp-coated implants in total hip arthroplasty (THA) and dental implants [57]. This served as a driving force for further studies to significantly improve the overall properties of the pure HAp. Till date, several efforts such as incorporation of reinforcing phases, introduction of buffer layers, controlling deposition parameters, application of pre/post treatments, and etc. have been suggested to overcome the challenges and shortages of pure HAp. By surveying the literature, it is not difficult to find experimental and review papers on the HAp-based composite coatings fabricated by various methods [31,38,[57], [58], [59], [60], [61], [62], [63], [64]].
However, to the best of our knowledge, there is no extended overview addressing the material-property relationships regarding in vitro and in vivo trials in the case of the composite and multilayer HAp-based coatings produced by RF magnetron sputtering. Following from the gap in the literature, the main purpose of this systematic review paper is to overview the most-promising strategies proposed for improve the final performance of RFMS'ed pure HAp coatings, i.e. incorporation of appropriate metallic and ceramic phases as well as application of favorable interlayer(s). The focus has been also put on drawing a meaningful relation between the parameters involved in fabrication of RFMS'ed HAp composite & multilayer coatings and their mechanical, electrochemical, and biological performance. The present review reveals the weak points and current perspectives of published papers so far, as well as suggests roadmaps for future research in this scope.
Section snippets
General aspects of RF magnetron sputtering
In general, magnetron sputtering (MS) is a rapid vacuum method that falls under the classification of physical vapor deposition (PVD) method. A typical magnetron sputtering coating device is composed of substrate holder, target, power supplier, vacuum pump, working gas, electric coils, magnets, and cooling water. The magnetron sputtering coating device makes it possible to grow films composed of pure metals, alloys, and compounds with thickness up to 5 μm. The power supply in this machine can
Background
Based on a generally agreed definition of composites, they are described as “materials fabricated by combining constituent materials having different properties and shapes to realize new properties which each constituent does not have by itself” [67]. In other words, the goal behind the preparation of a composite material is taking the full advantages of both matrix and reinforcements. In the case HAp-containing composite deposits, while HAp matrix possess spectacular biocompatibility and
Background
Generally, the different thermal expansion coefficients of the pure HAp bio-coating and most of the implants, in particular Ti and Ti alloys, has become a great challenge in the biomedical applications to be overcome. This issue may negatively affect the mechanical, corrosion, and biological performance of the bio-coatings. Several practical strategies including the application of interlayer(s) have been suggested to meet this priority, as it can drastically diminish the thermal expansion
Conclusions, challenges, and future perspectives
This systematic review considers attempts to illustrate the overall properties of RFMS'ed bioactive HAp-based composite and multilayer coatings. The practically employed approaches for producing such a coating system as well as their most important advantages and limitations are revealed. The correlation between the incorporated reinforcing phase(s) and interlayer(s), and physicochemical, mechanical, corrosion, and biological performance are comprehensively discussed. Based on the overviewed
Declaration of competing interest
The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Acknowledgements
JK-A and MSS would like to acknowledge the financial support from the vice chancellor for research of Sahand University of Technology.
RAS and MAS acknowledge the support of Tomsk Polytechnic University within the framework of the Tomsk Polytechnic University Competitiveness Enhancement Programme grant, Ministry of Science and Higher Education of the Russian Federation (State Project “Science” №WSWW-2020-0011).
References (226)
- et al.
The effect of process conditions on the properties of bioactive films prepared by magnetron sputtering
Vacuum
(2008) - et al.
A comprehensive review of biodegradable synthetic polymer-ceramic composites and their manufacture for biomedical applications
Bioact. Mater
(2019) - et al.
A critical review of decades of research on calcium-phosphate-based coatings: how far are we from their widespread clinical application?
Curr. Opin. Biomed. Eng
(2019) - et al.
Significance of calcium phosphate coatings for the enhancement of new bone osteogenesis–a review
Acta Biomater.
(2014) - et al.
Surface Modification of Biomaterials by Calcium Phosphate Deposition, Surface Modification of Biomaterials
(2011) Calcium orthophosphate deposits: preparation, properties and biomedical applications
Mater. Sci. Eng. C
(2015)- et al.
Calcium phosphate coatings for bio-implant applications: materials, performance factors, and methodologies
Mater. Sci. Eng. R
(2009) - et al.
Endothelialization and the bioactivity of Ca-P coatings of different Ca/P stoichiometry electrodeposited on the Nitinol superelastic alloy
Mater. Sci. Eng. C
(2016) - et al.
Biocompatibility of hydroxyapatite coatings deposited by pulse electrodeposition technique on the Nitinol superelastic alloy
Mater. Sci. Eng. C
(2017) - et al.
Bioactivity and electrochemical behavior of hydroxyapatite-silicon-multi walled carbon nano-tubes composite coatings synthesized by EPD on NiTi alloys in simulated body fluid
Mater. Sci. Eng. C
(2017)
On the electrocrystallization of pure hydroxyapatite nanowalls on Nitinol alloy using a bipolar pulsed current
J. Alloys Compd.
Effect of the deposition temperature on corrosion resistance and biocompatibility of the hydroxyapatite coatings
Appl. Surf. Sci.
Biocompatibility and corrosion behavior of the shape memory NiTi alloy in the physiological environments simulated with body fluids for medical applications
Mater. Sci. Eng. C
Influence of tantalum pentoxide secondary phase on surface features and mechanical properties of hydroxyapatite coating on NiTi alloy produced by electrophoretic deposition
Surf. Coating. Technol.
Electrophoretic deposition and characterization of bioglass-whisker hydroxyapatite nanocomposite coatings on titanium substrate
Surf. Coating. Technol.
Biomechanical compatibility and electrochemical stability of HA/Ta2O5 nanocomposite coating produced by electrophoretic deposition on superelastic NiTi alloy
J. Alloys Compd.
Adhesion of sol–gel derived hydroxyapatite nanocoatings on anodised pure titanium and titanium (Ti6Al4V) alloy substrates
Surf. Coating. Technol.
Influence of deposition conditions on the composition, texture and microstructure of RF-magnetron sputter-deposited hydroxyapatite thin films
Thin Solid Films
Hybrid biocomposite with a tunable antibacterial activity and bioactivity based on RF magnetron sputter deposited coating and silver nanoparticles
Appl. Surf. Sci.
In vivo dissolution behavior of various rf magnetron-sputtered CaP coatings on roughened titanium implants
Biomaterials
The structure of an RF-magnetron sputter-deposited silicate-containing hydroxyapatite-based coating investigated by high-resolution techniques
Surf. Coat. Technol.
Zn-, Cu- or Ag-incorporated micro-arc coatings on titanium alloys: properties and behavior in synthetic biological media
Surf. Coating. Technol.
MAO-preparation of nanocrystalline hydroxyapatite–titania composite films: formation stages and effect of the growth time
Mater. Res. Bull.
Study of the gradual interface between hydroxyapatite thin films PLD grown onto Ti-controlled sublayers
Appl. Surf. Sci.
Structural evolution and growth mechanisms of RF-magnetron sputter-deposited hydroxyapatite thin films on the basis of unified principles
Appl. Surf. Sci.
Lowering the resistivity of aluminum doped zinc oxide thin films by controlling the self-bias during RF magnetron sputtering
Surf. Coating. Technol.
Characterization and corrosion behavior of graphene oxide-hydroxyapatite composite coating applied by ultrasound-assisted pulse electrodeposition
Ceram. Int.
Ion-substituted calcium phosphate coatings deposited by plasma-assisted techniques: a review
Mater. Sci. Eng. C
Characterization, mechanical and in vitro biological behavior of hydroxyapatite-titanium-carbon nanotube composite coatings deposited on NiTi alloy by electrophoretic deposition
Surf. Coating. Technol.
Development of graphene oxide/calcium phosphate coating by pulse electrodeposition on anodized titanium: biocorrosion and mechanical behavior
J. Mech. Behav. Biomed. Mater
Biocompatibility assessment of graphene oxide-hydroxyapatite coating applied on TiO2 nanotubes by ultrasound-assisted pulse electrodeposition
Mater. Sci. Eng. C
The effect of graphene oxide on surface features, biological performance and bio-stability of calcium phosphate coating applied by pulse electrochemical deposition
Appl. Surf. Sci.
Enhancement of the mechanical properties of hydroxyapatite by SiC addition
J. Mech. Behav. Biomed. Mater
The structure of an RF-magnetron sputter-deposited silicate-containing hydroxyapatite-based coating investigated by high-resolution techniques
Surf. Coat. Technol.
Mechanical properties by instrumented indentation of solution precursor plasma sprayed hydroxyapatite coatings: analysis of microstructural effect
Surf. Coating. Technol.
Influence of microstructure and phase composition on the nanoindentation characterization of bioceramic materials based on hydroxyapatite
Ceram. Int.
C–HAp composite layers deposited onto AISI 316L austenitic steel
Surf. Coating. Technol.
One-step anodization deposition of anticorrosive bioceramic compounds on AZ31B magnesium alloy for biomedical application
Ceram. Int.
Microstructure and bond strength of HA (+ ZrO2+ Y2O3)/Ti6Al4V composite coatings fabricated by RF magnetron sputtering
Surf. Coating. Technol.
Fabrication and physico-mechanical properties of thin magnetron sputter deposited silver-containing hydroxyapatite films
Appl. Surf. Sci.
Mechanical properties of hydroxyapatite-zirconia coatings prepared by magnetron sputtering
Trans. Nonferrous Metals Soc. China
Effect of silicate doping on the structure and mechanical properties of thin nanostructured RF magnetron sputter-deposited hydroxyapatite films
Surf. Coating. Technol.
Mechanical properties and biocompatibility of the sputtered Ti doped hydroxyapatite
J. Mech. Behav. Biomed. Mater
Sputter deposition of calcium phosphate/titanium dioxide hybrid thin films
Mater. Sci. Eng. C
Evaluation of Ag containing hydroxyapatite coatings to the Candida albicans infection
J. Microbiol. Methods
The preparation of calcium phosphate coatings on titanium and nickel–titanium by rf-magnetron-sputtered deposition: composition, structure and micromechanical properties
Surf. Coat. Technol.
Nanomechanical properties of hydroxyapatite (HAP) with DAB dendrimers (poly-propylene imine) coatings onto titanium surfaces
Mater. Sci. Eng. B
Properties of (Ti, Cr, Al) N coatings with high Al content deposited by new plasma enhanced arc-cathode
Surf. Coating. Technol.
Phase composition of sputtered film from a mixture target of hydroxyapatite and strontium-apatite
J. Mater. Sci. Technol.
Radio frequency magnetron sputter deposition as a tool for surface modification of medical implants, Modern Technologies for Creating the Thin-film Systems and Coatings: Intech
Cited by (68)
Improved corrosion protection of a NiTi implant by an electrodeposited HAp-Nb<inf>2</inf>O<inf>5</inf> composite layer
2023, Surface and Coatings TechnologyCorrosion behavior of composite coatings containing hydroxyapatite particles on Mg alloys by plasma electrolytic oxidation: A review
2023, Journal of Magnesium and Alloys