Development of superlattice CrNNbN coatings for joint replacements deposited by High Power Impulse Magnetron Sputtering

The demand for reliable coating on medical implants is ever growing. In this research, enhanced performance of medical implants was achieved by a CrN/NbN coating utilising nanoscale multilayer/superlattice structure. The advantages of the novel High Power Impulse Magnetron Sputtering technology, namely its unique highly ionised plasma were exploited to deposit dense and strongly adherent coatings on Co-Cr implants. TEM analyses revealed coating superlattice structure with bi-layer thickness of 3.5 nm. CrN/NbN deposited on Co-Cr samples showed exceptionally high adhesion, critical load values of LC2= 50 N in scratch adhesion tests. Nanoindentation tests showed high hardness of 34 GPa and Young's modulus of 447 GPa. Low coefficient of friction (µ) 0.49 and coating wear coefficient (KC) = 4.94 x 10-16 m3N-1m-1 were recorded in dry sliding tests. Metal ion release studies showed a reduction in Co, Cr and Mo release at physiological and elevated temperatures, (70 oC) to almost undetectable levels (<1 ppb). Rotating beam fatigue testing showed a significant increase in fatigue strength from 349±59 MPa (uncoated) to 539±59 MPa (coated). In vitro biological testing has been performed in order to assess the safety of the coating in biological environment, cytotoxicity, genotoxicity and sensitisation testing have been performed, all showing no adverse effects. Keywords: Orthopaedic implant, High Power Impulse Magnetron Sputtering, Superlattice coating, Corrosion, Biocompatibility

Substrate finishing and niobium content effects on the high temperature corrosion resistance in steam atmosphere of CrN/NbN superlattice coatings deposited by PVD-HIPIMS

The main objective of this work was to evaluate the oxidation resistance of three PVD-HIPIMS CrN/NbN coatings, studying the effect of the surface finishing of the substrate and the role of niobium content into the coating composition. CrN/NbN nano-multilayered films on P92 steel were tested at 650°C in pure steam atmosphere. The mass gain was measured at fixed intervals to study their oxidation kinetics. The morphology and thickness of nanoscales were measured by transmission electron microscopy (TEM). Characterization of coatings before and after the thermal treatment was performed by scanning electron microscopy-energy with facilities of dispersive X-ray spectroscopy (SEM–EDX) and X-ray diffraction (XRD). All coatings improved the oxidation resistance of the substrate material, but the best behaviour was exhibited by the CrN/NbN with the high niobium (Nb) content and deposited on the substrate with the finest surface finishing