Design and characterisation of a new duplex surface system based on S-phase hardening and carbon-based coating for ASTM F1537 Co–Cr–Mo alloy

Co–Cr–Mo alloys are one of the most widely used metallic biomaterials for metal-on-metal joint prostheses. However, concerns over increased revision rates mainly due to nano-sized wear debris have been raised. This study was aimed at enhancing the friction, wear and load-bearing properties of Co–Cr–Mo alloys by developing a new duplex surface system combining super hard and wear-resistant S-phase layer with self-lubricating, low-friction carbon-based coating. To this end, ASTM F1537 Co–Cr–Mo alloy surface was plasma carburised (PC) at 450 °C and then coated with a carbon-based GiC coating. The microstructures of the duplex and single treated (PC or GiC coating) Co–Cr–Mo surface systems were characterized and their mechanical, tribological and corrosion properties were evaluated. The results showed that the new duplex surface system exhibited a high load bearing capacity, a low friction coefficient, excellent wear resistance and good corrosion behaviour.