Microplasma Sprayed Tantalum Coatings on Ti Grade 5 Extra-Low Interstitials: Investigation of Thickness and Porosity Control

This study investigates the microplasma deposition of molten tantalum (Ta) onto a rotating Grade 5 Ti Extra-Low Interstitial (ELI) alloy, producing multilayer film coatings with a porous microstructure. Optimal parameters for microplasma spraying Ta were experimentally determined to improve the surface properties of elbow joint implants. The physical and mechanical properties of the Grade 5 Ti ELI substrate and the Ta-based coating were analyzed. Moreover, mathematical modeling was utilized to determine the optimal parameters for the plasma coating process, including key factors such as spray distance, current, and rotational speed, which were systematically applied across three experimental series. A Ta coating thickness of 250 μm was achieved at 35 A current, 410 mm spray distance, and 7 rpm rotation speed under optimized deposition conditions. The results showed a microhardness increase on the Ta-coated surface, peaking above HV1000 with an average of HV742, while the Ti substrate averaged HV325. Additionally, the XRD patterns revealed the presence of metallic Ta alongside Ta oxides, such as Ta2O and Ta2O5, in the Ta coatings.