Hip and knee joint replacements have been some of the most successful surgeries for the treatment of patients with chronic pain due to arthritis. A current challenge is however the younger and more active patients, which demands longer-lasting devices that will withstand several decades of cyclic loading. Corrosion and wear products are herein a concern since they can cause localized inflammation leading to periprosthetic bone loss and potentially implant loosening, necessitating revision surgery. One approach to overcome the long-term issues is to develop materials more resistant to wear and corrosion, as well as materials giving less of an inflammatory response, e.g. by depositing a ceramic coating which acts as a barrier to the release of metal ions from the substrate as well as improving the wear resistance. Silicon nitride is a promising candidate because of its low wear rates and the possibility to limit the adverse effects of wear debris due to its slow dissolution in aqueous solutions.
Purpose of the study
This study aimed to investigate the dissolution and biocompatibility of SiCrNbN coatings deposited on cobalt chromium (CoCr) substrates. We hypothesized that the ceramic coating will reduce metal ion release compared to uncoated CoCr without affecting its biocompatibility.
MethodsThe SiCrNbN coatings were deposited on CoCr disc substrates by reactive sputtering in an in-house built equipment, allowing for combinatorial processes, using Si, Cr and Nb solid targets. Nitrogen was supplied as a reactive gas. To improve the adhesion of the coating a CrN interlayer was deposited. The coatings were characterized in 9 points using x-ray photoelectron spectroscopy (XPS), vertical scanning interferometry (VSI) and scanning electron microscopy (SEM). The points were placed in a 3x3 grid with 22.5 mm between each point.
The dissolution was evaluated by exposing the coated samples to cell media for 7 days. The obtained extracts were diluted (neat extracts (1:1), and 3 two-fold dilutions (1:2, 1:4 and 1:8)) and used to measure ion levels with inductively coupled plasma (ICP-OES) and to assess indirect biocompatibility in vitro using the tetrazolium dye MTT
and L929 fibroblast cells.
Results
The XPS results revealed compositional gradients with Si ranging between 27.4-32.8 at.%, Cr 4.1-10.9 at.%, Nb 3.5-8.4 at.%, N 41.8-46.8 at.% and O 10.9-14.6 at.%. SEM revealed coating thicknesses between 320-590 nm, and interlayers approx. 50 nm thick. Images displayed an overall smooth surface with an average roughness, Ra, of 5.6 to 9.3 nm, similar for all points. Grooves from polishing and occasional features at the microscale were observed, likely formed during deposition. The ICP results showed a reduction in Co ions from the substrate in the coated samples compared to uncoated. The cell viability results suggest that fibroblasts tolerated the neat extracts and their dilutions (1:1, 1:2, 1:4) obtained from the coated samples in a dose-dependent manner.
ConclusionsThe findings from this study suggest that the differences in composition did not affect the surface properties. The material characteristics indicate that silicon nitride has a promising potential to be used as a coating in metallic implants to improve corrosion resistance and reduce ion release, warranting further biological evaluation.