Effect of grain size and density of spray-pyrolyzed hydroxyapatite particles on the sinterability of hydroxyapatite disk

The effect of grain size and density of hydroxyapatite particles, which were prepared by different spray-pyrolysis temperatures, on the sinterability of hydroxyapatite disk was investigated. Calcium phosphate solution (Ca/P ratio of 1.67 and 0.1 M concentration) was prepared by reacting calcium nitrate tetrahydrate and diammonium hydrogen phosphate solutions, and adding nitric acid. Spray-pyrolysis was carried out at 900 °C, 1200 °C, and 1500 °C at a carrier gas flowing rate of 10 L/min. The particles synthesized at 900 °C were large, hollow spheres with a hole at the outer surface, a broad size distribution, but had small grain sizes. Conversely, the particles synthesized at 1500 °C were small, solid spheres with a narrow size distribution, but had large grain sizes. The particles synthesized at 1200 °C had intermediate properties. A sinterability test conducted at 1100 °C for 1 h demonstrated that small and dense particles with large grain sizes showed a higher relative sintered density compared with large and hollow particles with small grain sizes. The results were explained in terms of the grain size and density of a particle, which were inversely and proportionally affected to sinterability. The practical implication of these results is that highly sinterable hydroxyapatite powders can be synthesized through spray-pyrolysis at a high temperature under a fixed initial concentration of calcium phosphate solution and flow rate of carrier gas.