Processing of a multi‐layer polyetheretherketone composite for use in acetabular cup prosthesis

The hydroxyapatite polyetheretherketone (HAPEEK) as a non‐degradable bioactive polymer composite material with coating of hydroxyapatite (HA) as a bioactive ceramic material can enhance the osteointegration of carbon fiber reinforced polyetheretherketone (CFRPEEK) as a non‐degradable bioinert polymer composite. This study describes the joining process of CFRPEEK and HAPEEK beam components and coating process of HA on the HAPEEK substrate to achieve the multi‐layer PEEK composite for use in the application of acetabular cup prosthesis. The CFRPEEK and HAPEEK components were ultrasonically welded while the HA was plasma sprayed on the HAPEEK substrate. Ultrasonic welding parameters (length and direction of the energy directors at the interface, welding time, and pressure) were investigated by single cantilever beam and lap shear tests to achieve the optimum bonding strength of CFRPEEK and HAPEEK components. Plasma spraying parameters (e.g., surface speed, powder feed, current, primary gas flow, and system voltage) were altered to achieve the good adhesion of HA coating on the HAPEEK substrate, which was evaluated by scratch test. The results showed that the proposed multi‐layer composite was successfully processed by carrying out the ultrasonic welding and plasma spraying coating processes. The outcomes of this study could be used to develop a non‐metal acetabular cup prosthesis using the proposed multi‐layer composition. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40915.