Mechanical tests, wear simulation and wear particle analysis of carbon-based nanomultilayer coatings on Ti(6)Al(4)V alloys as hip prostheses

Carbon-based nanomultilayer coatings were deposited on medical-grade Ti(6)Al(4)V alloy using a magnetron sputtering technique under a graded bias voltage. The mechanical properties of the nanomultilayer coatings were investigated by nanoindentation, Rockwell and scratch tests as well as a ball-on-disk tribometer. The biological properties related to the immunological response of the coatings were investigated by wear simulation and wear particles analysis. Wear simulation was done according to ISO 14242, wear particles were analysed according to ISO 17853, and then compared with CoCr femoral heads. The results revealed that the carbon-based nanomultilayer coatings showed a multilayer structure, with a hardness of ∼20 GPa, an elastic modulus of ∼175 GPa, an adhesion higher than 80 N, and a low average coefficient of friction of 0.1. The average gravimetric wear rate of the polyethylene cups between the coated and CoCr groups had no statistical difference (P = 0.098). The average equivalent circle diameter of particles produced in the coated group was larger than that in CoCr (P = 0.001), but the proportion of submicron particles and globular/circular particles was not significantly different between the two groups (P > 0.05). Results showed lower Co/Cr ion contamination in the coated group. Hence, the carbon-based nanomultilayer coating on Ti(6)Al(4)V has good mechanical and tribological properties, releases fewer harmful metal ions and would not cause a more intense immunological host response than a CoCr prosthesis. The newly designed a-C nanomultilayer coatings are expected to prolong the longevity of artificial hip joints.