Microarc oxidation discharge types and bio properties of the coating synthesized on zirconium

- Different surface morphologies were synthesized with PEO method.
- Different surface morphology structures showed different apatite growth rate.
- The growth mechanism of the coatings was explained with different process times.

This study is an attempt for gaining a better understanding on relationship between microarc oxidation (MAO) coating discharge types and bioactivity of an oxide-based coating synthesized on a Zr substrate. The discharge types and the coating growth mechanism were identified by the examination of the real cross-section image of the coating microstructure. The coating was conducted by using MAO in an electrolyte containing Na2SiO3, Ca(CH3COO)2 and C3H7Na2O6P, for different durations of 2.5, 5, 15, and 30 mins. The effect of the process duration on the different discharge model types (Type-A, B, and C) and bioactivity of the coatings were investigated by using X-ray Diffractometry (XRD), Fourier Transform Infrared Spectroscopy (FTIR), Scanning Electron Microscopy-Energy-Dispersive X-ray spectroscopy measurements (SEM-EDS) and Optical Surface Profilometry (OSP). It was found that the increasing MAO duration resulted in thicker and rougher coatings. The XRD data revealed that all the samples prepared at different process durations contained the t-ZrO2 (tetragonal zirconia) phase. During the MAO process, non-crystalline hydroxyapatite (HA) formed, which was confirmed from the FTIR data. The surface morphology, the amount and distribution of the features of the coating surface were modified by increasing voltage. The simulated body fluid (SBF) tests showed that the more bioactive surface with more HA crystals formed owing to chemical composition and high surface roughness of the coating. The pore, crack and discharge structures played a key role in apatite nucleation and growth, and provided ingrowth of apatite into discharge channels on the coating surface.