PCSIR

PCSIR

PVD Hi-tech Coatings for Surgical Instruments

Dr. Shehzad AlamDirector General,

Pakistan Council for Scientific and Industrial Research, PCSIR, Lahore

Workshop on “Challenges & Potentials of Surgical Instruments Industry”

April 14, 2011

PCSIR

Format of Talk

• INTRODUCTION TO PITMAEM

• AREAS OF RESEARCH AND INTEREST

• AREAS OF NEW AND EMERGING TECHNOLOGIES

• PHYSICAL VAPOR DEPOSITION (PVD)

• BENEFITS OF PVD COATINGS

• BIO-MEDICAL APPLICATIONS

• TYPES OF INDUSTRIAL COATINGS PRODUCED

• CHARACTERIZATION

• CONCLUSION

PCSIRSATELLITE PICTURE

PITMAEM BUILDING

Pakistan Institute of Technology for Minerals and

Advanced Engineering Materials (PITMAEM)

PCSIR

Our Mission

• Conduct fundamental and applied research in the field of materials science and engineering.

• Develop new materials.

• Improve the performance of traditional engineering materials.

• Promote high quality scientific and engineering research, identifying the national need and help in its progress.

• Enhance interdisciplinary research and international collaboration.

PCSIR

Areas of Research

• Materials Processing

• Materials Characterization

• Materials Modeling

• Materials Properties and Performance

PCSIR

•Engineering composites

•Material characterization

•Mineral processing & mineral based chemicals

section

•Corrosion control studies section

•Electrometallurgy section

•Product development section

Areas of Interest

PCSIR

•Nano technology

•Non destructive testing

•Centre of excellence in industrial coatings

•Jewelry hallmarking

•Foundry technology

•Heat treatment & rolling

•Industrial chemicals

Areas of Interest

PCSIR

Targets of the country to strengthen the

economy

• Rapid industrialization,

• Export enhancement,

• Self-reliance and

• Minimizing the import could be the basic

targets.

PCSIR

Current Status

However, the engineering industries

• Automobile

• Textile

• Chemical

• Surgical etc

have failed to achieve the targets set for

deletion of imported parts. The reason for this

state of affairs can be attributed to the:

PCSIR

The reason for this state of affairs can be attributed to

the

• Inability of the local industry to

manufacture good quality products

due to use of out-dated techniques and

• lack of technical know how

PCSIR

The situation can be rectified byrestoring, the production of thoseengineering based parts locally. Toachieve these targets, capacitybuilding in science and technology is

quite vital.

PCSIR

Industrial based economic system

• What it means in actual terms is that the

agro- based-economic system should be

changed to industrial-based system. This

simple realization of the ground reality

requires action in certain areas.

PCSIR

Industrial based economic system

• We as scientists/engineers in Pakistan

must be able to identify the usefulness

and relevance of the technologies that

should be adopted or materials to be

developed. This is most essential to avoid

wastage of time, resources and the

materials

PCSIR

• The specific areas of the new and

emerging technology that need our

immediate attention pertain to the

following specific field.

AREAS OF NEW AND EMERGING

TECHNOLOGIES

PCSIR

• Powder metallurgy

• Composite Materials and Engineering

Ceramics

• Shape memory alloy

• Single crystals

AREAS OF NEW AND EMERGING

TECHNOLOGIES

PCSIR

• Special alloys for surgical and

biomedical applications

• High temperature alloys

• Plastics, composite plastics & ceramic

polymers

• Materials for sports industry

AREAS OF NEW AND EMERGING

TECHNOLOGIES

PCSIR

New magnetic materials & ceramicmagnets

Surface modification by plasma, CVD and PVD techniques

Nano-technology with special emphasis on Nano-materials and their characterization for engineering industrial applications.

AREAS OF NEW AND EMERGING

TECHNOLOGIES

PCSIR

Surface modification

• Surface modification is a valuabletechnique in order to producedesirable properties on surface ofthe material.

PCSIR

Surface Engineering

Electro -plating

Electro less-plating

CVD

PVD

Plasma Coating

CladdingAnodization

Bluing

TBC

EBPVD

Pack Cementation

PCSIR

Physical Vapor Deposition (PVD)

A vacuum deposition technique and is a

general term used to describe any of a variety

of methods to deposit thin films by the

condensation of a vaporized form of the

material onto various surfaces (e.g., onto steel

substrate).

PCSIR

The coating method involves purely physical

processes such as high temperature vacuum

evaporation or plasma sputter bombardment

rather than an involving a chemical reaction

at the surface to be coated.

Physical Vapor Deposition (PVD)

PCSIR

PVD Coating Centre

PCSIR

TYPES OF INDUSTRIAL PVD COATINGS PRODUCED IN

PITMAEM

PCSIR

TiN

The general purpose coating for:

• Cutting

• Forming

• Injection molding

• Tribological applications

PCSIR

TiCNConventional carbonitride coating for:

• For milling and tapping

• For stamping, punching and forming

PCSIR

TiAlN

• Dry machining

• Universal high-performance coating for:Cutting

• Monolayer: for stable finishing and roughing

• Multilayer: for interrupted cuts

PCSIR

AlTiN

• High-performance coating

• High aluminum content (>50%)

• High heat resistance

• For dry high speed machining

• Hard machining

PCSIR

µAlTiNSpecial high-performance coating:

• Finest Coating surface

• Highest edge stability

• Especially for precision machining (like reaming and tapping)

PCSIR

TiCN-MP

Standard gradient coating for

• Interrupted cutting

• Milling, Tapping, Hobbing

• Forming, Stamping and punching

PCSIR

CrN

The standard coating for

non-cutting applications:

• For molds and dies

• For machining parts

• Low deposition temperature possible (above

220˚C)

PCSIR

CBC CVIc

Double coating with nanogradient structure:

• For cutting sticky materials to avoid built up edges

• For forming application with optimum release

• For Tapping

PCSIR

ZrN

• Ti-free monolayer coating

• Effectively reduces the built up

edges when machining aluminum

and titanium alloys

PCSIR

nACo

• Nanocomposite coating

• nACo = (nc-AlTiN)/(a-Si3N4)

• Extremely High Nano Hardness

• High Heat Resistance

• Available with decorative blue top layer

PCSIR

nACRo

• Nano Composite coating

• nACRo=(nc-AlCrN/a-Si3N4)

• Extremely High Scratch Resistance

• High Heat resistance

• High Coating Thickness

• Specially for hobbing and Forming Tools.

PCSIR

Benefits of PVD Coatings on

Surgical Instruments

PCSIR

Benefits of PVD Coatings on

Surgical Instruments

The value of PVD technology rests in its

ability to modify the surface properties of

a device without changing the underlying

material properties and biomechanical

functionality.

PCSIR

Benefits of PVD Coatings on

Surgical Instruments

• PVD coatings provide a number of

benefits to surgical devices in

addition to hardness and adhesion.

• The most significant are listed below:

PCSIR

Key Benefits of PVD Coatings

on Surgical Instruments• Improved wear resistance

• Reduced friction

• Biocompatibility

• Decorative colors & aesthetic

• Chemical barrier

• Nickel Sensitivity

• Saline Solutions

• Sterilization

PCSIR

Benefits of PVD Coatings on

Surgical Instruments• PVD coatings on

surgical devices must

also be compatible

with the sterilization

process. Both TiN and

CrN resist corrosion

that can be caused by

steam and chemical

autoclaving.

Corrosion resistance of

PVD coatings after

medical sterilization

processes

PCSIR

Benefits of PVD Coatings on

Surgical Tools

• A variety of PVD coatings including

TiN, TiAlN and AlTiN are being used

on surgical tools.

• Examples are shown in next slides.

PCSIRTIN COATINGS ON SURGICAL

TOOLS

PCSIR

Benefits of PVD Coatings on

Orthopedic Implants

PCSIRBiomedical applications> Scratch Resistance on contact lenses > Materials properties on teeth materials

> Controlled drug release valves

> Hardness of bone tissue > Adhesion on coating for hip prostheses

> Scratch resistance

of arterial implants (Stents)

> Scratch Test on Breast Implants

> Blood Pump System

Pakistan Institute of Technology for Minerals and Advanced Engineering Materials (PITMAEM)

PCSIR

PCSIR

Benefits of PVD Coatings on

Orthopedic Implants• TiN has been in clinical use on orthopedic

implants for more than 9 years in North

America and Europe. The most common

applications involve total joint replacement

with Co-Cr-Mo or Ti-6-4 alloy implants.

• TiN is used for hip, knee, shoulder and

ankle implants.

PCSIR

Benefits of PVD Coatings on

Dental Tools

PCSIR

Benefits of PVD Coatings on

Dental Tools

• Dental instruments and orthodontic

devices are also coated with TiN in

order to provide resistance to germs

attack during surgery and routine

checkup etc.

PCSIR

Localized TiN Coating

PCSIR

Characterization Techniques

for PVD Coatings

PCSIR

CHARACTERIZATION TECHNIQUES FOR COATINGS

Following are the techniques most commonly used for

the characterization of these coatings

• Atomic Force Microscopy (Topographic Analysis)

• Nano Indentation (Mechanical Properties)

• Micro Scratch Testing (Adhesion)

• Pin/Ball on disc Tribometer (Tribology)

• Calotest ( Thickness Measurement)

• Scanning Electron Microscope

PCSIR

ANY QUESTIONS?

--

THANK YOU FOR YOUR KIND ATTENTION