Nano-porous alumina coatings for improved bone implant interfaces

A new method is proposed for coating implants that produces a metal implant covered in a layer of nano-porous alumina ceramic. These layers are produced by first depositing a layer of aluminium on the implant surface and then anodising it in phosphoric acid to produce the nano-porous structure. This process results in the conversion of the aluminium to alumina containing 6-8wt% phosphate ions. The surface alumina layer is bonded to the substrate via an interfacial layer of fully dense anodised titanium oxide. Mechanical measurements have shown that the shear and tensile strength of this coating are in excess of 20MPa and 10MPa, respectively. The biological performance of nano-porous alumina material has been assessed and shown to be highly favourable, supporting normal osteoblastic activity and maintaining the osteoblastic phenotype. The filling of the nano-porous coating with bioactive material to achieve enhanced biological performance has been investigated using colloidal silica as an analogue for a Bioglass sol. The coating has been loaded with silica by dipping in colloidal silica with a pH of 5.6. Pore filling equivalent to 1.3 wt% SiO2 in the coating as a whole has been achieved in this way