Synthesis and characterization of nanocrystalline CoCr coatings by plasma spraying

Abstract The present paper describes the synthesis and characterization of nanocrystalline CoCr (ASTM F75) coating produced by plasma spraying for possible surgical implant applications. The feedstock powders were synthesized by mechanical milling to produce irregular agglomerates with an average grain size of less than 100 nm. The powders were then introduced into an argon plasma spray to successfully produce a nanocrystalline coating. Scanning electron microscopy and transmission electron microscopy were used to study the morphology of the nanometric particles and the resultant sprayed coatings. Microhardness and porosity measurements were performed on the conventional and the nanocrystalline coatings to characterize and compare the physical and mechanical properties.