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The surface is a crucial part of a biomaterial in direct contact with organic tissues and body fluids. Often, the quality and durability of surfaces are decisive factors for the overall performance and reliability of the biomaterial components. For enhancement of the surface properties, cost-effective and reliable thermal spray techniques are used. The present research relates to thermal spraying of bio-active ceramic coatings. Reliable atmospheric plasma spray and innovative cold spray techniques were employed for coating deposition. Two different materials were used in this study: hydroxyapatite (HA), a wellestablished calcium phosphate ceramic material, and titanium dioxide (TiCh), a promising novel substitute for some conventional biomaterials. Wet chemical synthesis was used to produce pure hydroxyapatite powder. The powder was calcined (1273 K for 120mins) and sieved (32 45 um). Fused TiC>2 powder customized for atmospheric plasma spray was heat treated at 1023 K for 120 mins and sieved. Two focal points of this research work were: a) the changes in powder particles in-flight properties within the spray process due to the influence of various spraying parameters; and b) the changes in resulting coating properties due to changes in the in-flight properties For the plasma spray technique, the investigated parameters were the system net power, main, auxiliary and carrier gas flows, powder hopper feeder system revolutions per minute and spray distance. For the cold spray system, the parameters studied included electric current, process temperature, main gas and feeder gas pressures, and substrate materials. To determine the in-flight powder particle properties, fast-shutter diagnostics camera equipped with a laser illumination system was employed. In-situ temperature and velocity profiles of sprayed powder particles were scanned and recorded at different distances from the gun. To assess powder particles in-flight properties, two different experimental approaches were introduced. One-at-a-Time technique (OAAT) investigated the influences of the six spraying factors. The average temperatures and velocities of particles were measured as 2312 2674 K (201 341 ms") for HA and 2121 2621 K (158 243 ms") for Ti02. Spray distance was found to be the dominant factor for HA while net power and spray distance factor were found to have equally strong effect on the in-flight properties of TiC>2 particles. Carrier gasThe surface is a crucial part of a biomaterial in direct contact with organic tissues and body fluids. Often, the quality and durability of surfaces are decisive factors for the overall performance and reliability of the biomaterial components. For enhancement of the surface properties, cost-effective and reliable thermal spray techniques are used. The present research relates to thermal spraying of bio-active ceramic coatings. Reliable atmospheric plasma spray and innovative cold spray techniques were employed for coating deposition. Two different materials were used in this study: hydroxyapatite (HA), a wellestablished calcium phosphate ceramic material, and titanium dioxide (TiCh), a promising novel substitute for some conventional biomaterials. Wet chemical synthesis was used to produce pure hydroxyapatite powder. The powder was calcined (1273 K for 120mins) and sieved (32 45 um). Fused TiC>2 powder customized for atmospheric plasma spray was heat treated at 1023 K for 120 mins and sieved. Two focal points of this research work were: a) the changes in powder particles in-flight properties within the spray process due to the influence of various spraying parameters; and b) the changes in resulting coating properties due to changes in the in-flight properties For the plasma spray technique, the investigated parameters were the system net power, main, auxiliary and carrier gas flows, powder hopper feeder system revolutions per minute and spray distance. For the cold spray system, the parameters studied included electric current, process temperature, main gas and feeder gas pressures, and substrate materials. To determine the in-flight powder particle properties, fast-shutter diagnostics camera equipped with a laser illumination system was employed. In-situ temperature and velocity profiles of sprayed powder particles were scanned and recorded at different distances from the gun. To assess powder particles in-flight properties, two different experimental approaches were introduced. One-at-a-Time technique (OAAT) investigated the influences of the six spraying factors. The average temperatures and velocities of particles were measured as 2312 2674 K (201 341 ms") for HA and 2121 2621 K (158 243 ms") for Ti02. Spray distance was found to be the dominant factor for HA while net power and spray distance factor were found to have equally strong effect on the in-flight properties of TiC>2 particles. Carrier gas Nanyang Technological University i School of Mechanical and Aerospace Engineering ATTENTION: The Singapore Copyright Act applies to the use of this document. Nanyang Technological University Library

Thermally sprayed bio-ceramic coatings : a study on process parameters influence on coating properties