This project aims to address two major concerns with the use of hydroxyapatite [Ca10(PO4)6(OH)2, i.e., HA] coatings; i.e., (i) the resorption of the coating, and (ii) the resorption of bone. The objective is to optimize coating design through microstructural studies of two coating systems: a HA coating and a HA/polymer composite coating.; For the HA coating, the HA powders were atmospherically plasma sprayed (APS) using various process parameters. The phase, structure and microstructure of the coatings were investigated and the mechanical property and dissolution behavior measured. Both crystallinity and hydroxyl contents decreased with increasing spray power and stand-off distance (SOD), and increased from the coating interface to surface. Impurity phase contents increased with increasing spray power. Crystallinity alone cannot reflect coating quality due to the existence of various HA, i.e., unmelted, recrystallized and dehydroxylated, and the gradient structure. Coating microstructure varied from a porous structure to a smooth glassy structure or a typical lamellar structure, and some newly formed nanocrystalline regions were revealed. These effects were associated with the temperature-time experiences of particles, their cooling rates and the heat and hydroxyl accumulation during coating buildup.; Different coating properties and performance resulted from the characteristic differences. The coating with highest recrystallization displayed the highest microhardness. Dissolution of all coatings reached a saturation value much lower compared to their pulverized counterparts in a fresh solution despite a higher and similar dissolution in the initial immersion stage. The coating with higher recrystallization exhibited higher saturation value. Microstructural analysis indicated the complete and preferential dissolution of amorphous and impurity phases and some precipitation of apatite observable for coatings with higher recrystallization.; For the composite coating, HA/EMAA (ethylene methacrylic acid copolymer) coatings were produced using a flame spray system. The coatings exhibited increased Young's modulus compared to pure EMAA coatings and reasonable toughness and dissolution. The mechanical and dissolution behaviors were related to the volume and distribution of the HA in the polymer matrix. This technique provides a new means of preparing HA/polymer coatings for application as implants.
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