Comparison of one-step and sequentially irradiated ultrahigh-molecular-weight polyethylene for total joint replacements.

Structure and properties of several ultrahigh-molecular-weight polyethylenes (UHMWPEs), which were crosslinked either by standard, single-step irradiation or by newer, several-step irradiation (sequential irradiation), were compared. To verify the results, the same characterization was carried out for commercially available UHMWPE liners made of sequentially irradiated polymer (X3™, Stryker, Mahwah, NJ) and one-step irradiated polymer (denoted as PE-IMC, produced by Beznoska, Kladno, Czech Republic). The structure was studied by a number of spectroscopic, diffraction, thermal, and microscopic methods. Mechanical properties were assessed by small-punch, microhardness and, wear testing. Our results suggested that sequential irradiation followed by annealing did not lead to unusual structure at the molecular or supermolecular level. Consequently, all measured mechanical properties, including wear resistance, were comparable with one-step irradiated UHMWPEs.

Structural changes of UHMWPE after e-beam irradiation and thermal treatment.

Ultra-high molecular weight polyethylene (UHMWPE) was irradiated with accelerated electrons (1 MeV in air) using high dose rates (> 25 kGy/min) and thin specimens (thickness 1 mm). Parts of the specimens were remelted (200 degrees C for 10 min; 150 degrees C for 0, 2, 10, 30, 60 min). All specimens were stored in nitrogen in the dark at 5 degrees C. Supermolecular structure, extent of crosslinking, oxidative degradation, and macroradical content were studied by a number of methods (SAXS, WAXS, SEM, DSC, FTIR, ESR, TGA, solubility experiments, image analysis). The results obtained with irradiated samples were compared with those obtained with irradiated and remelted samples. It was confirmed that crosslinking predominates over chain scission at very high dose rates, even if the irradiation is performed in air. Discrepancies concerning supermolecular structure changes in UHMWPE after irradiation and thermal treatment, found in various studies in the literature, are discussed. A simple model, which describes and explains all supermolecular structure changes, is introduced. An effective way of eliminating residual macroradicals in UHMWPE is proposed.

Structure modification of UHMWPE used for total joint replacements.

Modification of ultrahigh-molecular-weight polyethylene (UHMWPE) consisting of a combination of gamma irradiation and subsequent thermal treatment has been performed in order to investigate the resultant changes to its supramolecular structure. In the first step the polymer was irradiated by gamma rays at laboratory temperature under nitrogen. Five radiation doses (25, 50, 100, 150, and 200 kGy) were applied at two dose rates (0.25 and 2.5 kGy/h). In the second step the irradiated samples were thermally treated above the UHMWPE melting temperature. Insoluble fraction, crystallinity (fraction), and lamellar periodicity were determined as functions of dose and dose rate for irradiated samples before and after thermal treatment. Both modification steps were shown to produce substantial changes in the UHMWPE structure.