Plasma Arc Sprayed Titanium Coating on Polished Zirconia
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Solution Overview
Problem
Existing metal or metal alloy porous coated ceramic materials for prosthetic implants, such as magnesium oxide stabilized zirconia, often exhibit inconsistent strength and reliability in bonding, which can lead to unreliable performance in load-bearing applications.
Innovation Solution
A method involving a fired magnesium oxide stabilized zirconia ceramic body with a highly smooth or polished surface coated with a metal or metal alloy, specifically using titanium or titanium alloy through plasma arc spraying under vacuum, providing an extraordinary holding power without the need for binders, and applying the coating to nonarticular surfaces of orthopedic implants like femoral and tibial components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal or metal alloy porous coating is applied to ceramic prosthetic implants, then coating strength and reliability can be improved, but bonding consistency remains inconsistent
Solution Approach 1:
The ceramic surface is polished to a highly smooth finish before coating application, preparing the surface in advance to ensure consistent and reliable bonding. This preliminary surface preparation eliminates variability in bonding strength by creating a uniform substrate condition that promotes consistent metal alloy coating adhesion across all implant pieces.
2Strength
If grooves or holes are formed in ceramic surface for coating attachment, then coating bonding can be enhanced, but manufacturing complexity and processing steps increase
Solution Approach 1:
Instead of creating mechanical interlocking features (grooves or holes) to enhance coating bonding, the invention inverts the approach by creating a highly smooth, polished surface that promotes bonding through surface quality rather than mechanical features. This eliminates the need for additional machining operations while achieving equivalent or superior bonding results.
3Reliability
If multiple processing steps are used to prepare ceramic surface for coating, then coating bonding reliability can be improved, but manufacturing efficiency decreases
Solution Approach 1:
The invention extracts and eliminates unnecessary intermediate processing steps (such as groove formation or hole machining) by directly applying the polished surface finish as the bonding interface. This streamlines the manufacturing process by removing redundant operations while maintaining coating bonding reliability through the polished surface alone.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves a highly reliable and strong bond between the ceramic and metal alloy, meeting or exceeding FDA requirements, with the coating able to withstand significant forces and reducing the risk of allergic reactions, while also simplifying manufacturing by eliminating the need for forming grooves or holes, thus enhancing the efficiency and reliability of orthopedic implants.
Implementation Method 1
A method to provide the article is provided, say, with plasma arc spraying under vacuum.
Implementation Method 2
A method to provide the article is provided, say, with plasma arc spraying under vacuum.
Data Source
AI summary
Fired magnesium oxide stabilized zirconia ceramic body having a highly smooth, polished or otherwise equivalent surface has, on at least part of the surface, a metal/metal alloy coating. The fired ceramic body can be a magnesium oxide stabilized tetragonally toughened zirconia. The coating can be from a metal or metal alloy other than by tantalum vapor deposition, and can include a titanium metal or alloy. The coated magnesium oxide stabilized zirconia ceramic can be a tool or an orthopedic implant or component for an orthopedic implant, which can be a load bearing implant or component for a load bearing implant having an articular surface and a nonarticular surface where the metal or metal alloy coating is on at least part of the nonarticular surface. Plasma arc spraying under vacuum may be employed.