Thermal barrier coatings of YSZ developed by plasma sprayed technique and its effective use in orthopedic and dental application.

The development of durable and biocompatible implant materials remains a critical challenge in the field of biomedical engineering, particularly for dental and orthopedic applications. In this study, yttria-stabilized zirconia (YSZ) coatings with varying molar percentages were deposited on Ti-6Al-4V alloy substrates using the plasma spraying technique. Structural analysis via X-ray diffraction (XRD) confirmed the presence of both transformable and non-transformable phases, with the latter offering enhanced phase stability advantageous for biomedical use. Scanning electron microscopy (SEM) of the cross-sectional morphology revealed that the 5 M% YSZ coating exhibited uniform thickness, low porosity, and absence of cracks, indicating good coating integrity. In vitro hemocompatibility tests with human blood demonstrated a hemolytic ratio below 5%, meeting the threshold for non-hemolytic biomaterials. Antibacterial assays showed notable inhibition against Escherichia coli, with moderate activity against Staphylococcus aureus. Cytocompatibility was evaluated using MG-63 osteoblast-like cells, where the 5 M% YSZ composite exhibited non-toxic behavior up to 250 µg/mL after 24 h of exposure. Mechanical testing further confirmed the coating's properties under simulated physiological conditions. These findings suggest that 5 M% YSZ plasma-sprayed coatings present a promising candidate for long-term dental and orthopedic implant applications, owing to their favorable mechanical strength, biocompatibility, and antibacterial properties.