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In this study, hydroxyapatite (HA) coatings were deposited on Ti-6Al-4V by micro-plasma spraying (MPS). The influence of the process parameters on the microstructure of HA coatings was investigated. The splat morphology and spreading behavior were examined to understand the influence of process parameters on the coating. The texture strength of HA coatings was characterized by X-ray diffraction (XRD). The texture coefficients were all applied to characterize the variation in texture. The morphology of splats and coatings were characterized by scanning electron microscopy (SEM). XRD pattern shows that the texture intensity of the c-axis of HA was greatly influenced by spraying distance and spraying current. SEM reveals the different texture strength of HA coatings with different ratios of columnar grains. The strongest c-axis texture was found in the coating by 60 mm spraying distance with a spraying current of 40 A. In the cross-section SEM images of the coating with the strongest c-axis texture, uniform distribution columnar grains were observed in the upper part (100 mu m). The investigation of splats indicates that columnar grain growth occurs after fully melted particles impact the heated substrate. By controlling the melting state prior to in-flight particle impacts, columnar grain growth can be achieved during slow solidification of the disk shape splat during MPS.
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