Mechanical Reliability Modification of Metal Matrix Composite Coatings by Adding Al Particles via Cold Spray Technology

Abstract Within biomedical applications, there is ever increasing research of lightweight, improved long-term performance, safe biocompatible and mechanical reliable bearing surfaces. Such efforts are being made to find materials with excellent mechanical properties able to meet the design requirements of medical implant applications, in order to manufacture competitive implant components. In this perspective, Cold Spray (CS) technology is used to deposit an oxygen sensitive material (e.g. Ti-6Al-4V & Al) and create a Ti-based Metal Matrix Composite (MMC) coating by the addition of Al particles. The microstructure of MMC coatings was modified, which subsequently changed the toughness of these coatings to reduce the susceptibility to crack. Surface roughness, coatings thickness, porosity and chemical composition results indicate that a CS deposition is a reliable and reproducible method to fabricate a MMC coating. The wear behaviour of this coating has been assessed and a higher amount of Al improves the coating's toughness through modification of hardness and wear resistance. This MMC coating could be a promising candidate that is being an undercoat in the damage tolerant coating system to ensure a reliable bearing surface for artificial joints with beneficial impact resilience and damage tolerance.