The fretting corrosion resistance of PVD surface-modified orthopedic implant alloys.

The objective of this study was to evaluate the fretting corrosion resistance of both modified and unmodified Ti6Al4V flats fretted against CoCr-alloy spheres in a buffered Hank's solution at 37 degrees C using an original fretting apparatus. A physical vapor deposition (PVD) cathodic arc evaporation technique was used to deposit 3-4 microm thick titanium nitride (TiN), zirconium nitride (ZrN), or amorphous carbon (AC) coatings onto the Ti6Al4V substrates. The fretting behavior of the nitride films (TiN and ZrN) was characterized by the absence of surface damage and the deposition of a Cr-rich oxide transferred from the CoCr-alloy spheres to the modified surfaces. This oxide led to a slight increase in surface roughness. Three of the six multilayered AC coatings tested exhibited extensive fretting damage and generated large, deep, wear scars. Cohesive failure of the AC coating was observed in the low contact stress areas of the fretting scars. The remaining AC-coated specimens experienced only slight polishing wear. The reason for the different behavior within the AC-coated specimens is not clear at the present time. The unmodified Ti6Al4V surfaces experienced severe surface damage consistent with the adhesive galling mechanism to which these alloys are susceptible. Copyright 2001 John Wiley & Sons, Inc.