Accepted Manuscript Micro-arc oxidation coating on porous magnesium foam and its potential biomedical applications
J.M. Rúa, A.A. Zuleta, J. Ramírez, P. Fernández-Morales PII: DOI: Reference:
S0257-8972(18)31431-2 https://doi.org/10.1016/j.surfcoat.2018.12.106 SCT 24177
To appear in:
Surface & Coatings Technology
Received date: Revised date: Accepted date:
4 September 2018 23 December 2018 25 December 2018
Please cite this article as: J.M. Rúa, A.A. Zuleta, J. Ramírez, P. Fernández-Morales , Micro-arc oxidation coating on porous magnesium foam and its potential biomedical applications. Sct (2018), https://doi.org/10.1016/j.surfcoat.2018.12.106
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ACCEPTED MANUSCRIPT Micro-arc oxidation coating on porous magnesium foam and its potential biomedical applications J. M Rúa 1,*, A.A. Zuleta2, J. Ramírez3, P. Fernández-Morales 4
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70-01, Medellín, Colombia
Grupo de Investigación de Estudios en Diseño - GED, Facultad de Diseño Industrial,
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2
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Facultad de Ingeniería Aeronáutica, Universidad Pontificia Bolivariana, Circular 1ª. Nº
3
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Universidad Pontificia Bolivariana, Circular 1ª. Nº 70-01, Medellín, Colombia Facultad de Minas, Universidad Nacional de Colombia, Cra. 80 # 65-223, Medellín,
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Colombia 4
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Facultad de Ingeniería Industrial, Universidad Pontificia Bolivariana, Circular 1ª. Nº
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70-01, Medellín, Colombia
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Abstract
In this study, we fabricated a biodegradable porous metal using the AZ31 Mg alloy
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substrate with anodic coating for application in bioimplant scaffolds. The cellular Mg alloy was obtained by employing replication processes that use NaCl as a space holder
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under a controlled atmosphere. Further, vacuum pressure was applied for achieving the infiltration. The Mg porous samples were coated by a micro-arc oxidation (MAO) technique using a phosphate/calcium electrolyte. Further, the samples were examined by atomic force microscopy (AFM), scanning electron microscopy (SEM), X-ray diffraction (XRD), compression tests and surface area measurements. The MAO technique allowed
*
corresponding author Tel.: +57 4 448 83 88 Ext.12177 E-mail:
[email protected]
ACCEPTED MANUSCRIPT us to obtain a homogeneous coating layer of ~16.0 µm thickness with the surface across the foam structure comprising rounded pores with diameters of less than 3.0 µm. Ca, P, Mg and O are the main elements of the anodic coating. Furthermore, both the coated and uncoated porous samples exhibit similar values of approximately 1.5 GPa and 5.0 MPa for the Young’s modulus and compressive strength, respectively.
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Keywords: Magnesium foam, Micro-arc oxidation, Inorganic coating, Infiltration
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process, Cancellous bone, Biodegradable Mg.
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1. Introduction
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Several studies have been conducted to investigate whether magnesium (Mg) and its alloys can be considered to be suitable candidate materials for developing medical
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implants because of their properties such as good biocompatibility, non-toxicity and high specific strength [1–5]. Therefore, porous Mg structures, such as foams, have also been
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investigated as scaffolds because the biomimetic structure of the open porous foam
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ensures the chemical stability of implants while a patient is healing. Despite the aforementioned advantages, Mg exhibits low ductility and poor creep as well
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as corrosion resistance, which has limited its application as a biomaterial [6]. Further, a previous study implies that the presence of Mg in human body results in a favourable
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environment for the growth of bone cells [7]. Additionally, this effect can be improved when the surface area of the material is increased [8], which is similar to that observed in case of metal foams. This indicates that the porous morphology of the Mg alloy foams allows bone regeneration because of the presence of an appropriate osteoconductive environment. Furthermore, the mechanical behaviour of the AZ31 Mg foams is highly similar with that of the cancellous bone tissue having a Young’s modulus and compressive strengths of 2.0 GPa and 0.2–80 MPa, respectively, which effectively
ACCEPTED MANUSCRIPT reduces the stress shielding induced between the implants and surrounding bone tissue [9–11]. Mg and its alloys are known to exhibit a high chemical/electrochemical activity that could lead to corrosion failures in different surroundings, including biological environments [12]. Further, hydrogen gas bubbles are generated owing to the anodic reaction that occurs
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during the Mg corrosion process. This hydrogen generation increases proportionally with
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the Mg dissolution rate [13] and inhibits cell attachment, causing inflammation of the
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surrounding tissue [1]. In case of Mg foams, this phenomenon is considerably pronounced because of the large surface area [14]. Therefore, developing new processes for
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conducting surface treatments of Mg substrates is necessary to improve their surface properties, thereby enabling the usage of Mg and its alloys in biological environments.
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This constitutes an interesting subject of research, which focuses on obtaining
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biodegradable materials with good biocompatibility and adjustable corrosion rates.
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The micro-arc oxidation (MAO) technique, which is also known as plasma electrolytic oxidation (PEO), improves the corrosion behaviour and wear resistance of metal substrates, such as titanium, aluminium and magnesium alloys, through the formation of
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a strong, thick, relatively porous and adherent ceramic film exhibiting minimal changes
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in the substrate properties. The MAO technique exhibits surface modification with promising results for preventing corrosion along with the potential biomedical application of Mg and Mg alloys in bulk [15]. Technically, the MAO technique uses conventional anodised Mg. The applied voltage and current are considered to be important for initiating the MAO technique and for creating a circuit that allows the oxidation of a metal surface employed as the anode [16]. The MAO technique parameters, such as current density, voltage, cathode metal,
ACCEPTED MANUSCRIPT conductivity and pH electrolyte, as well as some substrate factors, such as microstructure and chemical composition, strongly influence the coating properties. The phosphate and silicate electrolytes are commonly used because of their optimal conductivity, and each of these electrolytes exhibit respective characteristic responses [17]. Specifically, the phosphate electrolyte accelerates the discharge process and allows rapid coating growth,
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which is considered to be an advantage for the application of this technique to samples
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with a large exposed area [16–19].
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In particular, the MAO coatings are being developed on Mg alloys to enhance their biocompatibility with coatings similar to bone tissue. In this case, phosphate coatings are
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considered to be good candidates for improving the bioactivity and biodegradation properties of the substrate [20]. Because the calcium phosphate compounds are important
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for functionalising the surface metal, researchers have employed some salt types as
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alternatives for phosphate electrolytes [21–23].
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No Mg porous materials that have been successfully modified with MAO have been reported to date. Therefore, to establish MAO coating on AZ31 alloys, studies, such as the one conducted by Li et al. [24], were evaluated. Li et al. used a sodium phosphate
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solution to obtain a biocompatible surface, where the final reaction formed products that
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exhibited both hydroxyapatite and calcium phosphate phases. Similarly, Chen et al. [25] coated AZ31 with a combination of silicate and phosphate using NaOH to adjust the pH level. Furthermore, other solutions have been applied to protect the Mg substrates, among which silicates have also been applied [26–28]. Despite the fact that the AZ31 Mg alloy is already coated by means of the MAO process using a phosphate electrolyte, we failed to find any reports on the application of MAO coatings on Mg foams during our literature review. Thus, we assume that this study is the first to describe the Mg foam that has been treated with MAO. The objective of this study
ACCEPTED MANUSCRIPT is to investigate the formation of MAO coating on AZ31 Mg foams using an electrolyte comprising calcium and phosphorus. Further, the mechanical properties, chemical composition and morphology of the coatings were assessed. The presented coatings are
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potentially suited to protect the Mg foams in biomedical applications.
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2. Experimental details
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2.1.1 Magnesium foam fabrication
The AZ31 Mg foams (wt. %: 3 Al, 1 Zn, bal. Mg) were produced using the infiltration
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process under the conditions that were reported in a previous study [29]. Further, the NaCl particles were used as space holders with a size ranging between 500 and 600 µm. The
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argon gas that was combined with the salt fluxes was used as the control atmosphere for performing the Mg melting process, and the infiltration was performed under vacuum
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conditions. The infiltrated material comprising AZ31/NaCl was cut and mechanised into
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cylinders having a diameter of ~8.0 mm. The samples height to mechanical test was of 16 mm and 4.0 mm to morphological characterisation. To reveal the porous structure, the
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specimens were cleaned using deionised water in an ultrasonic bath for 15 minutes. Further, the samples underwent pickling with 80% nitric acid and were neutralised with
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40% sodium hydroxide, rinsed in deionised water and dried in an air stream. This process was terminated when the value of electroconductivity became ~97.0 µS/cm. 2.1.2 MAO coating process The MAO process was conducted in potentiostatic mode for 5 min using the Matsusada power supply (1000 W). The electrolyte was prepared by dissolving NaOH, Ca(OH)2, Ca(HPO4), and metallic calcium in 8 L of deionised water with a final alkalinity and electroconductivity of pH 12.5 and 96.7 µS/cm [30], respectively. The bath was stirred
ACCEPTED MANUSCRIPT during the process using a magnetic stirrer at 600 rev/min. Further, a two-electrode electrochemical cell was employed using a stainless steel vessel as the cathode. Subsequently, the specimens were immediately rinsed in ethanol and dried in a cool air stream. Each experiment was performed thrice to verify the reproducibility.
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2.1.3 Metal foam characterisation The average roughness for uncoated and coated foam, (Ra) and (Rq), respectively, was
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assessed by atomic force microscopy (AFM) using the Infinity Asylum (Oxford
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Instruments) Research MFP-3D microscope. The analysis area was 20 × 20 μm using a
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silicon tip with a diameter of 9.0 nm for conducting topographic measurements. To measure the surface area of coated specimens, degassing of the specimen was
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conducted overnight at a temperature of 110 °C and a vacuum pressure of 1 × 10−6 mbar; the adsorption/desorption isotherms of a pressure sorption were obtained using a
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Micromeritics ASAP 2020 Surface Area and Porosity Analyzer. Further, the N2 gas was
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used for obtaining adsorption isotherms, and the pore size distribution was analysed using
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the density functional method (DFT).
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2.1.4 Coating characterisation The morphological and chemical composition examination of the coatings was conducted by scanning electron microscopy (SEM) using the JEOL 6490LV instrument, equipped with energy dispersive X-ray (EDX) spectroscopy (OXFORD INCAPentaFET-x3). Further, cross-sections of the coatings were prepared by polishing using SiC paper (#120, #320, #400, #600 and #1200 grit), followed by polishing with diamond to a roughness of 1 μm, and were further rinsed with ethanol and dried in a cool air stream.
ACCEPTED MANUSCRIPT The coating composition was investigated by X-ray diffraction (XRD) using an X'Pert APD X-ray diffractometer with Co Kα radiation. The data were recorded over the 2θ range of 10°–80°, with a step size of 0.02°. In addition, a Fourier transform infrared spectroscopy (FTIR) was employed to identify the phosphate compounds in the coating
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using a Shimadzu (FTIR) Model Tracer-100 in the spectral range from 400 to 4000 cm−1.
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2.1.5 Mechanical characterisation
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Finally, the mechanical compression response was determined under a uniaxial
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compression load using the Instron 3366 Universal testing machine (Instron Corp., USA) with a crosshead speed of 0.50 mms−1. The compression tests were conducted on the
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cylindrical specimens having a height of 16.0 mm at room temperature in accordance
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with the ISO 13314 standard (compression test for porous and cellular metals) [31].
3. Results and discussion
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3.1 MAO coating
The current and voltage–time response during the MAO process for the AZ31 Mg foam
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is presented in Figure 1.
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Figure 1. Current and voltage–time plots during the potentiostatic MAO process of the AZ31 magnesium
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alloy foam at 500 V.
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A curve with three main segments is observed in agreement with previous reports [16,32]: (i) a current increase from 0 to 2 A is observed due to the formation of a barrier layer
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[33], which is followed by the initial state of the constant current that lasts for up to 50 s,
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corresponding to an initial galvanostatic period; (ii) subsequently, the voltage becomes constant, and a decrease in current to 1 A is observed using the fluctuations that are caused
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by localised sparks on the surface of the AZ31 foam; (iii) finally, the current is stabilised until the end of the process at ~0.65 A. Further, it is important to mention that the applied
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current during the MAO process was experimentally fixed because the Mg foam suffered severe corrosion at low current values and because the formed coating was considered to be unsatisfactory owing to the presence of cracks and corrosion products.
3.2 Morphology, surface area and density of AZ31 foams Figure 2
(a) and (b) depict the SEM images of the uncoated and coated AZ31 Mg foam
morphologies. The uncoated foam exhibits a uniform pore distribution with
ACCEPTED MANUSCRIPT interconnected pore sizes of between 100 and 500 μm. Further, the pore size and morphology replicates the shape of the salt particles that are used as space holders, which is an observation that is characteristic of the infiltration process [29, 34–36]. The porosity percentage of the AZ31 Mg foam can be determined using the following expression: 𝑃𝑟 (%) = (1 − 𝜌𝑅 ) × 100,
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(1)
where Pr (%) denotes the porosity percentage and ρR denotes the relative density of the 𝜌
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foam, equivalent to the ratio between the foam and bulk Mg densities ( 𝐹 ) [37–39]. The 𝜌𝐵
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Pr (%) was 35.679% ± 0.011% and 53.381% ± 0.002% for uncoated and coated foams,
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respectively. These results are similar to those reported for the Mg foams obtained by the same infiltration process [14,40]. This result is important with respect to the biomedical
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field because the minimal porosity values for applications in cancellous, cortical or trabecular bones lie between 35% and 80% [8]; further, angiogenesis occurs in sites or
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cavities with mean diameters of between 100 and 500 μm [41–43].
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After the MAO coating process is completed, the AZ31 Mg foam relative density was observed to be ~28% lower than that of the uncoated foam (1.093 ± 0.003 for uncoated
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foam and 0.724 ± 0.019 for coated foam). The porosity percentage measured using the physisorption technique was 50.6%, which was 38% higher than that of the uncoated
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foam. This could be explained by the fact that the MAO coating process involves the surface dissolution of the Mg substrate, which is replaced by a porous coating layer [44,45]. The surface morphology of the coated AZ31 Mg foam is depicted in Figure 2 (a). This coating exhibits a homogeneous layer with a volcano-like morphology presenting circular pores and some coalescent pores, which are randomly distributed across the foam surface (Figure 2 (b)). The pore formation is typical of MAO processing on light metals. Further,
ACCEPTED MANUSCRIPT pores are formed by the discharges and gas evolution across the metal surface of the sample [16,46–48]. Such pores have sizes in the micro-/nano-scale, with diameters ranging from 3.0 to 8.5 µm in case of micropores. Further, the porous surface at the nanoscale level measured using the physisorption technique shows a bimodal pore distribution, with one peak around 8.3 nm and another peak between 18.5 and 50 nm. Some studies
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have implied that the nanopores that are present in the coating may decrease the corrosion
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resistance. Thus, the coating with nanopores may establish degradation control [49–52].
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This decrease in corrosion velocity is considered to be favourable while controlling the degradability and bioabsorbability of the Mg scaffolds. From this viewpoint, the MAO
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process ensures the porous morphology surface of the AZ31 foam that may enhance the bone cell adhesion, while the Mg scaffold is being metabolised by the body [17,53].
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Figure 2 (c) demonstrates the circularity of the pores on the coating, where a homogeneous distribution of large pores can be observed. Regardless, some micropores
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can be observed, confirming the pore distribution on the coating.
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A cross-section of the coated specimen is depicted in Figure 2 (d). The cross-section exhibits a relatively uniform thickness of 16.3 µm, with pores that tend to be distributed
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throughout the coating thickness.
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Figure 2. SEM images of (a) the uncoated magnesium foam, (b–c) surface of the MAO-coated AZ31 Mg
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foam, (d) cross-section of the MAO-coated AZ31 Mg foam.
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The surface topography three-dimensional images that are obtained by AFM for the uncoated and coated AZ31 magnesium foams are observed in Figure 3 (a) and (b),
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respectively. The uncoated foam exhibits a softer surface when compared with that exhibited by the coated foam, which can be attributed to the little holes that are present on the coated surface foam. The coating layer includes volcano-type pores with valleys and peaks between approximately 2.0 and 1.7 μm, increasing the roughness from Ra = 380.09 ± 97.73 nm (Rq = 477.063 ± 120.75 nm) for uncoated foam to Ra = 658.55 ± 107.483 nm (Rq = 831.876 ± 111.86 nm) for coated foam, which is an increase of approximately 57%.
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(a)
(b)
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Figure 3. AFM of the AZ31 magnesium foam surface topography for (a) uncoated foam and (b) coated foam.
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Reports have observed that cell adhesion is improved when the roughness becomes greater than 200 nm [8,54]. The surface area, measured using DFT analysis, yields values of 0.0260 and 6.845 m2/g for uncoated and coated foams, respectively. Both the results imply the presence of a Mg foam with a sufficiently large exposed area and a minimum roughness (200 nm) for cell anchoring. However, the increase in the surface area of the Mg foam after the MAO process could be attributed to the formation of a porous magnesium oxide layer. This is relevant because of the following two reasons: (i) while
ACCEPTED MANUSCRIPT maintaining porosity, large surface areas lead to better anchoring and colonisation sites for the cells [4,20,55,56] and (ii) the porosity of the oxide layer allows to control the corrosion rate of Mg, thereby avoiding its total degradation [40,57]. The aforementioned aspects suggest that the coated AZ31 foams become a potential biodegradable or bioabsorbable implant [34,58–60]. The SEM and AFM analysis present the AZ31 foams
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as materials with an interconnected porous and rough surface that exhibits appropriate
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topographic conditions for promoting cell growth and for the possible proliferation of
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bone cells [41,61].
Figure 4 (a) depicts the XRD patterns of the coated and uncoated AZ31 foams. The
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difference between both the samples can be observed in the signals corresponding to magnesium oxide (MgO) and calcium phosphate (CaP) that appear on the pattern of the
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coated sample [18,62,63]. The low intensity of CaP peaks can be attributed to the low amount of this compound or the presence of an amorphous phase [64]. Because rapid
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cooling of ceramic particles may occur during the MAO process, the presence of
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amorphous CaP on the coating is a possibility [64]. Previous studies have reported that the CaP compound hydroxyapatite-type signals are present in a range of 2θ = 25°–30°
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[21,47]. Further, CaP coating may enhance the biocompatibility of an implant-body
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because it presents a chemical composition similar to that of the bone, thereby avoiding the inclusion of elements that are located outside the body. In addition, these coatings prevent direct contact between Mg and the body fluids. This may result in a low corrosion level of Mg, thereby facilitating cellular proliferation [21,65,66]. To detect the presence of the nanocrystalline phase, Infrared spectroscopy (IR) spectroscopy was conducted as a complementary technique for the chemical characterisation of the coating. The IR spectra in Figure 4 (b) exhibit bands at 628, 1041
ACCEPTED MANUSCRIPT and 1502 cm−1, which are associated with PO−3 4 , and confirm the presence of the CaP
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compound, as previously exhibited by energy dispersive spectroscopy (EDS).
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(a)
(b) Figure 4. (a) XRD patterns for uncoated and coated foams and (b) IR for coated foam
ACCEPTED MANUSCRIPT Ca3O8P2 and MgO were detected in small amounts in the coating because MgO is a hard compound with less dissolution, while Ca3O8P2 is used to develop osteoconductive biomaterials [67,68]. Figure 5 illustrates the elemental distribution, denoting the homogeneous distribution of Ca and P. The surface mapping exhibits that the predominant elements of the coating are
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not preferentially segregated. Further, the chemical composition and elemental
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distribution of the coating were obtained using EDS analysis that presented the following
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results in wt. %: Mg: 31.92; O: 36.68; Al: 2.01; P: 19.52; and Ca: 9.87. This supports the results that have been obtained from the XRD and IR spectra. The XRD analysis did not
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exhibit any high intensity peaks associated with calcium phosphates; however, the EDS and mapping demonstrated that the compounds that are abundant in phosphorus and
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calcium are not segregated at preferential sites, possibly because they are present in small
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quantities.
Figure 5. Elemental mapping of the MAO coating on the AZ31 foam.
3.3 Mechanical characterisation
ACCEPTED MANUSCRIPT The nominal stress–strain curves of the uncoated and coated samples are presented in Figure 6. Both the uncoated and coated Mg foams exhibited similar mechanical behaviours with similar values of Young’s modulus and compression strength (Table 1), which indicated that surface modification does not affect the mechanical properties of the AZ31 Mg foam [69]. The AZ31 magnesium foam presents an elastic region and exhibits
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considerable strain with respect to other porous metals such as titanium foams.
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Specifically, the Mg foam presents a considerable strain for a stress of approximately 5.0
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MPa, which indicates an elastic region with a low stiffness that is similar to the values
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obtained by the cancellous bone [70–72] .
Figure 6. Compression stress vs strain curve for the uncoated and coated foams. Insert denotes the elastic zone.
According to Ashby et al. [37,73], Young’s modulus is inversely proportional to the foam porosity, which indicates the possibility that the mechanical properties can be modulated with respect to the particular bone application requirements. In this sense, when compared to bulk implants, metal foams present a considerably good alternative for osteointegration
ACCEPTED MANUSCRIPT to reduce the stress shielding effect [37,40,74,75]. The aforementioned data indicate that the obtained Mg foam could be a potential alternative for application as a bone scaffold because the pore size and porosity promotes osseointegration while offering good
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biomechanical behaviour [34,60].
1.484 ± 0.340
Coated AZ31 foam
1.452 ± 0.008
Magnesium foams
1.2–4.46
Titanium foams
0.40–50
Natural bone Cancellous bone
[8,76]
23–102
[34,43,60]
0.1–20.0
2.0–180
[69,77]
0.01–2.00
0.2–80
[70–72]
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[78]
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5–46
3–23
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4. Conclusions
This work
5.88 ± 0.211
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Cortical bone
References
5.347 ± 0.351
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Uncoated AZ31 foam
Compression strength (MPa)
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Young’s modulus (GPa)
Specimen
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Table 1. Comparative mechanical properties of the coated and uncoated foams with respect to other studies.
The electrical parameters of the MAO process were adapted for samples with
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considerable amount of exposed areas, such as magnesium foams, to yield coating with pore sizes of less than 3.0 μm and a layer thickness of ~16 μm as well as to obtain a chemical composition that is close to that of the bone tissue. These conditions contribute to obtain better anchoring of the cells. The AZ31 Mg foam density was ~28% lower than that of the uncoated foam, while the porosity of the coated foam was 38% higher than that of the uncoated foam. In addition, there was an increase in roughness, which can be considered to be an advantage because
ACCEPTED MANUSCRIPT it may enhance the cellular activity. Hence, the MAO coating can be considered to be an alternative for application on magnesium foams as a potential material for the medical implants industry. The chemical composition of the coating obtained using calcium phosphate compounds indicates that the coating exhibits a potential to be used as a biomaterial because these
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compounds contain the main elements that constitute the bone system, thereby alleviating
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the allergic reactions and other traumas that are associated with the presence of a foreign
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material inside the body.
Further, the mechanical compression tests did not show significant differences between
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the coated foam and the uncoated foam. Additionally, the Young’s modulus is observed
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to be within the range of values that is required for bone tissue applications.
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Acknowledgements
The authors are grateful to “Centro de Investigación para el Desarrollo y la Innovación (CIDI)” from the Universidad Pontificia Bolivariana through UPB-Innova
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Rad: 635B-06/16-18 and “Departamento Administrativo de Ciencia, Tecnología e Innovación (COLCIENCIAS) of the Colombian Government (Contract N°392-2016).
ysis.
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The authors also thank Prof. Zulamita Zapata for collaboration in the DFT tests and anal-
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Graphical Abstract
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Highlights
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MAO coatings on AZ31 magnesium foam obtained with satisfactory results. Magnesium foam was coated with friendly alkali electrolyte getting a homogeneus coating. Magnesium foam with surface and mechanical behavior are like cancellous bone. The porosity and chemical composition of MAO coating do not show harmless for biological applications.
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