Plasma-sprayed hydroxyapatite (HA) coatings are used on metallic implants to improve osseointegration and bone growth. The purpose of this work was to determine the microstructure and composition of HA coatings obtained with a newly developed low energy plasma spray mini-gun employing an HA feedstock powder with smaller granulometry than that commonly used. The microstructure and the phase composition of the coatings obtained by varying the number of mini-gun runs were examined using scanning electron microscopy, X-ray diffraction and Fourier transform infrared and micro-Raman spectroscopy. In all cases, the results indicate the presence of an amorphous phase and oxyapatite in the coatings due to hydroxyl group removal. No other foreign crystalline phases were detected. The absence of foreign phases was attributed to the fast cooling rate of the small particles used in the experiments and the low amount of energy employed with the mini-gun. Decomposition in the υ 1 PO 4 region of the Raman spectra allowed a semi-quantitative evaluation of the phase contents as a function of the number of runs. Micro-Raman spectroscopy appears to be a powerful technique providing comprehensive and localised information concerning calcium phosphate phases in coatings.

Self-lubricated coatings have been a major topic of interest in thermal spray in the last decades. Self-lubricated coatings obtained by thermal spray are exclusively based on solid lubricants (PTFE, h-BN, graphite, MoS 2 , etc.) embedded in the matrix. Production of thermal spray coatings containing liquid lubricants has not yet been achieved because of the complexity of keeping a liquid in a solid matrix during the spraying process. In the present article, the first liquid-solid self-lubricating thermal spray coatings are presented. The coatings are produced by inserting lubricant-filled capsules inside a polymeric matrix. The goal of the coating is to release lubricant to the system when needed. The first produced coatings consisted solely of capsules for confirming the feasibility of the process. For obtaining such a coating, the liquid-filled capsules were injected in the thermal spray flame without any other feedstock material. Once the concept and the idea were proven, a polymer was co-sprayed together with the capsules to obtain a coating containing the lubricant-filled capsules distributed in the solid polymeric matrix. The coatings and the self-lubricated properties have been investigated by means of optical microscopy, Scanning Electron Microscopy, and tribological tests.

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