ASTM F1147 Tension Testing for Calcium Phosphate and Metallic Coatings

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ASTM F1147 Standard Test Method for Tension Testing of Calcium Phosphate and Metallic Coatings

ASTM F1044 is a standard procedure for determining the tensile adhesion or cohesion strength of coatings on metallic substrates. It is specifically designed for continuous calcium phosphate coatings (e.g., hydroxyapatite) and metallic porous coatings bonded to dense metal substrates. The test applies a uniaxial tensile load perpendicular (normal) to the coating plane to evaluate the integrity of the bond between the coating and substrate (adhesion) or the strength within the coating material itself (cohesion).

Test Principle:

The core principle of ASTM F1147-24 is to subject an assembled specimen (one coated + one/more uncoated dense metal components) to pure axial tensile load perpendicular to the coating’s surface plane, eliminating eccentric loading and bending stresses that would skew results. A tensile testing machine applies load at a constant rate until the specimen assembly fully separates.

A tensile load is applied normal to the plane of the coating until failure occurs. The failure stress is calculated as:

S = F / A

where:

S = Adhesion or cohesion strength (MPa or psi)

F = Maximum load to failure (N or lbf)

A = Cross-sectional area of the coated substrate (cm² or in²)

The mode of failure (adhesive at the interface or cohesive within the coating) is identified and reported..

ASTM F1147 Specific Test Methods:

ASTM F1147 defines a single axial tensile test method for both calcium phosphate and metallic porous coatings, with minor bonding variations based on coating type:

Calcium phosphate coatings: The coated and uncoated specimen components must be bonded with a polymeric adhesive (film or filled viscous cement) that meets minimum tensile strength requirements.

Metallic porous coatings: Components may be bonded with the same polymeric adhesive or sintered together (direct thermomechanical bonding, no adhesive).

For all bonding approaches, the tensile load is applied uniformly and axially normal to the coating surface, and the test is terminated only when complete separation of the specimen assembly occurs. The standard also includes dedicated sub-procedures for bonding with different commercial adhesives (FM 1000, 3M Scotch-Weld, Masterbond, Loctite) to ensure test repeatability.

Test Equipment required for the ASTM F1147:

Universal Testing Machine	A tensile testing machine conforming to ASTM E4; Load range matching tensile strength measurement needs; a fixed cross-head speed of 0.25 cm/min (0.10 in./min); ability to accurately record the maximum failure load.
Gripping Devices	Grips must ensure purely axial tensile loading, aligning the specimen axis with the machine's centerline. he primary gripping device for pin-loaded specimens (with drilled holes), featuring two perpendicular dowel pins to minimize off-axis loading. Components include a double yoke, dowel pins, sample holder, and sample mating threads.
Adhesive Bonding Materials	Polymeric adhesives must have a minimum bulk tensile strength of 34.5 MPa (5000 psi). For porous coatings, adhesives must be sufficiently viscous to avoid penetrating through the coating to the substrate. Reference adhesive: FM 1000 Adhesive Film (0.25 mm/0.01 in. thickness)
Calibrated high-temperature springs	Applies a constant curing stress of 0.138 MPa (20 psi) to adhesive-bonded assemblies for uniform bonding.

Test Specimen Information:

Assembly Types: The test assembly consists of either two solid pieces (one coated, one uncoated) or three solid pieces (two uncoated with a coated piece in between). The uncoated surface may be roughened to aid bonding.

Critical Dimension: The cross-sectional area of the substrate where the coating is applied shall be a nominal 5.07 cm² (0.78 in²). Use of a different area requires demonstrating data equivalence.

Preparation Requirements:

Specimens must be coated using production feedstock lots and the same equipment used for actual medical implants.

All standard post-coating processes (thermal treatment, passivation, and sterilization) used for the final device must be replicated on test specimens unless proven not to influence strength.

100% visual inspection is required before testing. Specimens with a lack of coating in high-stress regions or non-uniform appearance must be rejected.

ASTM F1147 test procedures detaisl guide:

Step 1: Specimen Fabrication	Fabricate coated/uncoated metal components to the standard nominal cross-sectional area (5.07 cm²/0.78 in²) using production feedstock and equipment. Apply the coating (calcium phosphate/metallic) via production-scale techniques and perform all required post-treatments (heat treatment, passivation, sterilization). Clean and degrease all bonding surfaces to remove loose particles/beads; roughen uncoated surfaces if needed for better adhesion.
Step 2: Adhesive Bonding & Curing	Cut FM 1000 film adhesive to match the specimen’s shape/dimensions (use multiple layers for porous coatings). Align the adhesive at the center of the coated surface and apply a constant curing stress of 0.138 MPa (20 psi) using a calibrated high-temperature spring; maintain perfect alignment of the coating and counterface. Cure the assembly in an oven at 176°C (350°F) for 2–3 hours (optimize time for oven type/load; initial optimization without coatings is recommended). Cool the cured assembly to room temperature and remove excess protruding adhesive without damaging the specimen’s integrity.
Step 3: Specimen Mounting	Mount the cured/sintered assembly in the Yoke and Dowel Pin Grips such that the specimen’s long axis is coincident with the axial tensile load direction (aligned with the grip centerline).
Step 4: Load Application	Apply tensile load at a constant cross-head speed of 0.25 cm/min (0.10 in./min). Continue the test until complete separation of the specimen components occurs. Record the maximum failure load (F) for each specimen.
Step 5: Calculation & Reporting	Calculate the coated substrate’s cross-sectional area (A) to the nearest 0.006 cm²/0.001 in² and compute tensile strength (S = F/A). Compile a test report with mandatory data: material/adhesive identification, coating application details, dimensional data, number of specimens, failure load values (max/min/mean), and failure mode (cohesive/adhesive) for each specimen.

Importance of the Test for Materials:

This test is critically important for materials used in load-bearing medical implants, such as orthopedic and dental devices. Coatings like hydroxyapatite or porous metals are applied to enhance bone integration (osseointegration).

The tension test evaluates:

Coating Integrity Under Tensile Stress: Ensures the coating is robustly attached and will not delaminate under tensile forces experienced in vivo, which could lead to implant failure, particle debris, and adverse tissue reactions.

Process Validation and Control: Provides a key quantitative metric to validate that coating application parameters (spraying, sintering, heat treatment) produce a consistent and reliable bond strength.

Safety and Performance Assurance: Serves as a vital quality control check to ensure that only coatings meeting minimum strength requirements are used in human implants, thereby supporting patient safety and long-term clinical success.

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ASTM F1147 is a standard test method for ambient-temperature tensile testing of calcium phosphate and metallic porous coatings on dense metal substrates, Its core purpose is to evaluate the adhesion strength between coatings and substrates and the internal cohesion strength of coatings.

Coating static shear strength testing refers to ASTM F1044, F1160 standard, evaluating the shear force of continuous calcium phosphate coating or metal coating on the substrate, or the bonding strength between coatings parallel to the horizontal plane after shearing.

Q1: What is the purpose of the ASTM F1147 test?

A: The purpose is to measure the tensile adhesion or cohesion strength of continuous calcium phosphate (e.g., hydroxyapatite) and metallic porous coatings bonded to dense metal substrates. It applies a uniaxial tensile load perpendicular (normal) to the coating plane to determine the force required to pull the coating off or cause it to fail internally.

Q2: What does the test specimen look like, and how is it prepared?

A:Assembly: The test specimen is an assembly of either two solid pieces (one coated, one uncoated) or three solid pieces (two uncoated with a coated piece sandwiched in between). The uncoated surface may be roughened to improve bonding.

Critical Requirement: Specimens must be representative of actual implants. They must be coated using production materials and equipment, and undergo all the same post-coating processes (thermal treatment, passivation, sterilization) as the final medical device.

Inspection: Before testing, 100% visual inspection is required. Specimens with coating defects in high-stress areas or non-uniform appearance must be rejected.

Q3: What is the key step in preparing the test assembly?

A: The core preparation step is bonding the coated component to its uncoated counterpart.

For Calcium Phosphate Coatings: Bonding must be done using a high-strength polymeric adhesive.

For Metallic Coatings: Bonding can be done with an adhesive or by sintering the components together.

Adhesive Requirement: The adhesive (e.g., FM 1000 film) must have a bulk tensile strength of at least 34.5 MPa (5000 psi) or be stronger than the expected coating strength.

Curing: A typical procedure involves curing the assembly in a fixture under mild pressure (e.g., 0.138 MPa) at 176°C (350°F) for 2 to 3 hours.

Q4: What must be included in the test report?

A: The report must include: identification of all materials and the adhesive used; coating application method; specimen dimensions (bond area, coating thickness); number of specimens tested; all individual failure loads (maximum, minimum, mean); and most importantly, the documented mode of failure (cohesive vs. adhesive) for each specimen.

Q5: How does the bonding method differ for calcium phosphate vs. metallic coatings in this test?

A: A key distinction exists in bonding:

Calcium phosphate coatings: Coated and uncoated specimen components must be bonded with a polymeric adhesive (film or viscous cement) that meets minimum tensile strength requirements.

Metallic porous coatings: Components can either be bonded with the same polymeric adhesive or sintered together (direct thermomechanical bonding, no adhesive required).

Q6: What are the core dimensional requirements for ASTM F1147-24 test specimens?

A: The nominal cross-sectional area of the coated substrate is 5.07 cm² (0.78 in²)—alternative areas require proof of equivalence to this standard and must be explicitly reported. Specimens are assembled as 2-piece (1 coated + 1 uncoated) or 3-piece (2 uncoated + 1 single-side coated) solid metal components, with strict alignment to ensure tensile stress is normal to the coating surface.

Q7: Can ASTM F1147 test results be used to calculate a coating’s environmental stress resistance?

A: No. The standard explicitly states test results are heavily influenced by processing variables (e.g., substrate preparation, coating technique, post-coating heat treatment) and do not provide intrinsic values. Results are used for comparative evaluation (e.g., coating type/process performance) and quality control—not direct engineering calculations for environmental stress resistance.

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