Boron nitride nanoplatelets induced synergetic strengthening and toughening effects on splats and their boundaries of plasma sprayed hydroxyapatite coatings

Boron nitride nanoplatelets (BNNPs) with excellent mechanical properties were introduced into HA coatings fabricated through plasma spray in this research. SEM observation and Raman results revealed the added BNNPs retained their original structure even after harsh process and distributed homogeneously in the as-sprayed coatings. As compared with the monolithic HA coating, a 2.0 wt%BNNP/HA coating exhibited significant improvement (~ 40.3%) in fracture toughness and moderate enhancement (~ 20.0%) in indentation yield strength. Synergetic strengthening and toughening mechanisms which are operative through splat boundaries and individual splats were proposed. At splat boundaries, these embedded BNNPs induced stronger adhesion between the adjacent splats to resist splat sliding, which is evident from the fact that the calculated inter-splat friction force of an as-sprayed BNNP/HA coating was increased by ~7.3% at 2.0% BNNP weight fraction. Within splats, toughening mechanisms such as BNNP pullout, crack bridging by both anchored BNNPs and nanosized HA grains, crack deflection and crack propagation arrested by the embedded BNNPs were observed to improve toughness. Moreover, thermal mismatch between HA matrix and BNNPs during cooling process after plasma spray would induce the pre-existing dislocations formed around these BNNP nanofillers, which was assumed to hold out the effect of Orowan-type strengthening within splats.