Speedy bioceramics: Rapid densification of tricalcium phosphate by ultrafast high-temperature sintering

Highlights: • Ultrafast high-temperature sintering, UHS, allows consolidation of TCP in • The UHS samples possess a density exceeding 93%. • Heating and cooling rates exceeding 1200 °C min⁻¹ are achieved during UHS. • The UHS current allows tailoring the microstructure and mineralogical composition. • The UHS artifacts do not possess any cytotoxic activity. Due to unique osteogenic properties, tricalcium phosphate (TCP) has gained relevance in the field of bone repair. The development of novel and rapid sintering routes is of particular interest since TCP undergoes to high-temperature phase transitions and is widely employed in osteoconductive coatings on thermally-sensitive metal substrates. In the present work, TCP bioceramics was innovatively obtained by Ultrafast High-temperature Sintering (UHS). Ca-deficient hydroxyapatite nano-powder produced by mechanochemical synthesis of mussel shell-derived calcium carbonate was used to prepare the green samples by uniaxial pressing. These were introduced within a graphite felt which was rapidly heated by an electrical current flow, reaching heating rates exceeding 1200 °C min⁻¹. Dense (> 93%) ceramics were manufactured in less than 3 min using currents between 25 and 30 A. Both β and α-TCP were detected in the sintered components with proportions depending on the applied current. Preliminary tests confirmed that the artifacts do not possess cytotoxic effects and possess mechanical properties similar to conventionally sintered materials. The overall results prove the applicability of UHS to bioceramics paving the way to new rapid processing routes for biomedical components.