Ca-P bioactive coating prepared by combining microwave-hydrothermal and supersonic atmospheric plasma spraying methods

•Ca-P coating was prepared by microwave hydrothermal combined with spraying method.•Shear strength between coating and substrate was enhanced by 60% using new method.•The coating showed reactivity in stimulated body fluid.

Ca-P based coatings on carbon/carbon composite (C/C) were manufactured via a combined method comprising of microwave-hydrothermal (MH) and supersonic atmospheric plasma spraying (SAPS) techniques. However, a weak mutual interaction between the coating and C/C substrate has been a critical issue for a long time. Herein, we reported a new method for shear strength enhancement without compromising the osteoconductivity and osteoproductivity. Results showed that the inner layer has a strong mechanical interlocking with C/C substrate and the failure mode of outer layer changed from the coating cohesion (within the coating) to adhesive (at the coating/substrate interface) fracture. The shear strength between Ca-P bioactive coating-C/C substrate by MH/SAPS was significantly improved as compared to that prepared by SAPS. The Ca-P bioactive coating exhibited a good bioactivity as evidenced by the formation of a uniform carbonate-apatite layer formed on coating after immersing into stimulated body fluid for a specified period of time.