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In this research, hydroxyapatite powder particles were coated on a Ti-6Al-4V alloy substrate by the plasma spraying method to create bone implants by benefitting from titanium's mechanical properties and hydroxyapatite's biological properties. Hydroxyapatite prepared by the plasma spraying method suffers from decomposition, formation of other calcium phosphate phases, weak adhesion to the substrate, and microcrack formation in the coating due to residual stresses initiated by the high temperature of the coating process. To improve the hydroxyapatite coating properties, the Ti-6Al-4V alloy was preheated, and then hydroxyapatite coating took place. The results showed that residual stress in the interface decreased, and adhesion improved by preheating the substrate. However, formation of an amorphous phase on coating was observed, resulting in a higher dissolution rate in the biological environment and weak mechanical properties compared to crystalline hydroxyapatite. Experimental results showed that heat treatment after the coating process decreased the amount of this amorphous phase and heightened the crystallinity of the coating by up to more than 60%.

Hydroxyapatite nanoparticles coating on Ti-6Al-4V substrate using plasma spray method