Calcium phosphate (CaP) coatings on carbon fabric substrate were produced by sonoelectrodeposition at different current densities (5, 8, 13, 20 and 34 mA/cm2). The surface morphology and chemical composition of the coatings were characterized by SEM, Raman and FTIR spectra. The results showed that at 5 mA/cm2 current density, the coating exhibits plate-like morphology, indicating an octacalcium phosphate (OCP) phase was pre-formed in the deposits and then converted into hydroxyapatite (HA). When the current density was increased to 8 mA/cm2 and higher, the coatings exhibited needle-like morphology corresponding to a HA phase. Furthermore, the sonoelectrodeposited CaP coating exhibited denser and more uniform structures with smaller crystal sizes as the current density increased. Cathodic reaction mechanisms of CaP coatings on carbon in the sonoelectrochemical processes are proposed to explain the different kinds of calcium phosphate obtained.

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Calcium phosphate was deposited on carbon materials using a sonoelectrochemical method in an electrolyte containing calcium and phosphate ions. The effect of electrolyte concentration on sonoelectrochemically deposited calcium phosphate coatings was investigated and the underlying deposition mechanisms were discussed. The morphology, size and composition of the crystalline deposits changed with the electrolyte concentration. A mixture of plate, sphere and needle-like deposits was obtained at Ca(2+) ion concentrations greater than 16 mM, however needle-like hydroxyapatite (HA) was obtained at lower Ca(2+) concentrations. Analysis revealed that the sonoelectrochemical deposition of calcium phosphate consists of two processes-nucleation and crystal growth. The results suggest that the homogeneous nucleation of calcium phosphates in solution, followed by their absorption onto the carbon surface may account for the mechanism of coating observed at higher ionic concentrations. At lower concentrations, heterogeneous nucleation occurs on the surface of the carbon fibres, followed by the development of islands of crystal growth. The lower ionic concentration was shown to favour the generation of hydroxyapatite on carbon-based materials.