The effect of microplasma spraying parameters on the particle size and surface structure of tantalum coatings on Ti-6Al-4V alloy implants
S. Voinarovych
, S. Kaliuzhnyi
, O. Kyslytsia
, D. Alontseva
, E. Koytchev
, A. Alexiev
Abstract: Objective: The article is devoted to studying the influence of microplasma spraying (MPS) process parameters on the size of particles formed from tantalum (Ta) wire and their effect on the formation of the surface topography of Ta coatings on a Ti-6Al-4V alloy substrate, aimed at improving the biocompatibility of medical implant surfaces. Materials and methods: Using mathematical experimental design and scanning electron microscopy (SEM) analysis, the particle size was studied as a function of the MPS parameters. Surface roughness evaluation was performed using the Sa (Arithmetical Mean Height) and Sq (Root Mean Square Height) area roughness parameters. Results: The minimum particle size obtained was 101.0 ± 19.53 μm, while the maximum reached 282.0 ± 58.0 μm. Using processing parameters corresponding to the largest particles formation, coatings with a roughness of Sa = 15.28 ± 0.84 μm and Sq = 19.02 ± 0.82 μm were obtained. The results show that Ta particle size in the MPS process is governed by current intensity and wire feed rate: higher values lead to finer particles due to enhanced melt overheating and plasma jet effects, while lower values result in larger particles. Discussion: Optimization of these parameters enabled the formation of Ta coatings with developed surface topography and increased roughness, with Sa = 15.28 ± 0.84 μm, which is three times higher than after gas-abrasive treatment. Conclusion: The coatings show roughness favorable for bone ingrowth and osseointegration, however, pore optimization and further biocompatibility studies are needed to balance biological and mechanical properties.
Series on Biomechanics, Vol.40, No. 2 (2026), 3-14
DOI: 10.7546/SB.40.02.01.2026
Keywords: biocompatible coatings; Endoprostheses; tantalum (Ta); thermal plasma spraying
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| Date published: 2026-07-17
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