Silicon nitride (SiNx) coatings have recently been introduced as a potential material for joint implant bearing surfaces, but there is no data on wear debris morphology nor their dissolution rate, something that could play a central role to implant longevity. In this study, wear debris was generated in a ball-on-disc setup in simulated body fluid. After serum digestion the debris was analysed with scanning electron microscopy and energy-dispersive x-ray spectroscopy. The particle dissolution rate was evaluated using inductively coupled plasma techniques, on model SiNx particles. The wear debris from SiNx coatings was found to be round, in the nm range and formed agglomerates in the sub-micron to micron range. Model particles dissolved in simulated body fluid at a rate of: c(t)=39.45[1-exp(-1.11·10^-6t)], where [c(t)]=mg/l and [t]=s. This study can be used as a preliminary prediction of size, shape and dissolution rate of wear debris from SiNx coatings.

Silicon nitride (SiN_x) coatings are promising for joint replacement applications due to their high wear resistance and biocompatibility. For such coatings, a higher nitrogen content, obtained through an increased nitrogen gas supply, has been found to be beneficial in terms of a decreased dissolution rate of the coatings. The substrate temperature has also been found to affect the composition as well as the microstructure of similar coatings. The aim of this study was to investigate the effect of the substrate temperature and nitrogen flow on the coating composition, microstructure and mechanical properties. SiN_x coatings were deposited onto CoCrMo discs using reactive high power impulse magnetron sputtering. During deposition, the substrate temperatures were set to 200 °C, 350 °C or 430 °C, with nitrogen-to-argon flow ratios of 0.06, 0.17 or 0.30. Scanning and transmission electron spectroscopy revealed that the coatings were homogenous and amorphous. The coatings displayed a nitrogen content of 23–48 at.% (X-ray photoelectron spectroscopy). The surface roughness was similar to uncoated CoCrMo (p = 0.25) (vertical scanning interferometry). The hardness and Young’s modulus, as determined from nanoindentation, scaled with the nitrogen content of the coatings, with the hardness ranging from 12 ± 1 GPa to 26 ± 2 GPa and the Young’s moduli ranging from 173 ± 8 GPa to 293 ± 18 GPa, when the nitrogen content increased from 23% to 48%. The low surface roughness and high nano-hardness are promising for applications exposed to wear, such as joint implants.

Ceramic coatings deposited on orthopedic implants are an alternative to achieve and maintain high wear resistance of the metallic device, and simultaneously allow for a reduction in metal ion release. Silicon nitride based (SiN_x) coatings deposited by high power impulse magnetron sputtering (HiPIMS) have shown potential for use in joint replacements, as a result of an improved chemical stability in combination with a good adhesion. This study investigated the effect of N, C, Cr, and Nb content on the tribocorrosive performance of 3.7 to 8.8 µm thick SiN_x coatings deposited by HiPIMS onto CoCrMo discs. The coating composition was assessed from X-ray photoelectron spectroscopy and the surface roughness by vertical scanning interferometry. Hardness and Young’s modulus were measured by nanoindentation and coating adhesion was investigated by scratch tests. Multidirectional wear tests against ultrahigh molecular weight polyethylene pins were performed for 2 million cycles in bovine serum solution (25%) at 37 °C, at an estimated contact pressure of 2.1 MPa. Coatings with a relatively low hardness tended to fail earlier in the wear test, due to chemical reactions and eventually dissolution, accelerated by the tribological contact. In fact, while no definite correlation could be observed between coating composition (N: 42.6–55.5 at %, C: 0–25.7 at %, Cr: 0 or 12.8 at %, and Nb: 0–24.5 at %) and wear performance, it was apparent that high-purity and/or -density coatings (i.e., low oxygen content and high nitrogen content) were desirable to prevent coating and/or counter surface wear or failure. Coatings deposited with a higher energy fulfilled the target profile in terms of low surface roughness (Ra < 20 nm), adequate adhesion (L_c2 > 30 N), chemical stability over time in the tribocorrosive environment, as well as low polymer wear, presenting potential for a future application in joint bearings.

Ceramic coatings may prolong the lifetime of joint implants. Certain ions and wear debris may however lead to negative biological effects. SiN-based materials may substantially reduce these effects, but still need optimization for the application. In this study, a combinatorial deposition method enabled an efficient evaluation of a range of Si–Fe–C–N coating compositions on the same sample. The results revealed compositional gradients of Si (26.0–33.9 at.%), Fe (9.6–20.9 at.%), C (8.2–13.9 at.%) and N (39.7–47.2 at.%), and low oxygen contaminations (0.3–0.6 at.%). The mechanical properties varied with a hardness (H) ranging between 13.7–17.3 GPa and an indentation modulus (M) between 190–212 GPa. Both H and M correlated with the Si (H and M increased as Si increased) and Fe (H and M decreased as Fe increased) content. A slightly columnar morphology was observed in cross-sections, as well as a surface roughness in the nm range. A cell study revealed adhering pre-osteogenic MC3T3 cells, with a morphology similar to that of cells seeded on a tissue culture plastic control. The investigated coatings could be considered for further investigation due to the ability to tune their mechanical properties while maintaining a smooth surface, together with their promising in vitro cell response.

The addition of alloying elements, in particular chromium, reduced the dissolution rate of silicon nitride coatings without affecting other functional properties such as hardness. Optimum chromium contents gave an enhanced in vitro cell viability.

The possibility of decreasing the dissolution rate of SiN coatings using Fe and C is promising and the released ions were demonstrated to be compatible with microglia viability, in both 2D cultures and 3D collagen hydrogels.