Contact stress assessment of conventional and highly crosslinked ultra high molecular weight polyethylene acetabular liners with finite element analysis and pressure sensitive film.

Stress magnitude and distribution of both conventional polyethylene versus a crosslinked polyethylene in the liner of a total hip replacement (THR) were examined using finite element analysis and pressure sensitive film. Both types of polyethylene were assessed against head sizes of 22 and 28 mm with 5-mm thick polyethylene liners and head sizes of 28, 38, and 46 mm with 3-mm thick polyethylene liners. Liners with 5-mm conventional polyethylene represented successful combinations with long track records. Our hypothesis was that although the combination of the large head and the lower modulus of the highly crosslinked polyethylene would lead to lower stresses, the stresses would be excessive if the liner was extremely thin at 3 mm. Von Mises stresses at the articulating surface of the highly crosslinked liners were lower, when compared to conventional polyethylene, in every THR size examined. Specifically, however, the 38- and 46-mm inner diameter (ID) highly crosslinked polyethylene even at the extreme of only 3-mm thick had lower stresses than the 22-mm ID conventional liner of 5-mm thickness. These data indicate that the use of a large head against highly crosslinked material even at 3-mm thickness results in lower stresses than in an existing conventional 22-mm head and 5-mm thick combination. Obviously, other considerations will influence the minimum thickness to be recommended.

Knee-simulator testing of conventional and cross-linked polyethylene tibial inserts.

We compared the resistance to delamination and to adhesive/abrasive wear of conventional and highly cross-linked polyethylene tibial inserts of a cruciate-retaining total knee design using a knee simulator. Both groups were tested after aggressive, accelerated aging, and 1 set of conventional inserts was studied without aging. Aging oxidized the conventional, but not the highly cross-linked, inserts. The simulated normal gait testing lasted for 5 and 10 million cycles for the conventional and highly cross-linked inserts, respectively. Aged conventional inserts showed delaminations, whereas none were observed in the unaged conventional and aged cross-linked inserts. Wear rates measured by the gravimetric method were 9 +/- 2 mm3, 10 +/- 4 mm3, and 1 +/- 0 mm3 per million cycles; by the metrologic method, they were 8 +/- 1 mm3, 9 +/- 2 mm3, and 3 +/- 0 mm3 for the unaged conventional, aged conventional, and aged highly crosslinked inserts, respectively. In the test model used, oxidation led to delamination, whereas increased cross-link density resulted in reduced adhesive/abrasive wear of tibial inserts.

Third-body wear of highly cross-linked polyethylene in a hip simulator.

The wear performance of a radiation cross-linked melted ultrahigh-molecular-weight polyethylene (UHMWPE) articulating against 28-mm cobalt chrome femoral heads in the presence of third-body particulate debris was investigated in a hip simulator and compared with the wear of conventional UHMWPE. Particles of aluminum oxide or bone cement containing barium sulfate were added to the serum. In the presence of aluminum oxide particles, the incremental wear rates of conventional UHMWPE averaged as high as 149 +/- 116 mg/million cycles compared with 37 +/- 38 mg/million cycles for the highly cross-linked components. The difference in the average weight loss was statistically significant at P <.01. With bone cement particles, the conventional UHMWPE components had an average incremental wear rate of 19 +/- 5mg/million cycles, and the wear rate of the highly cross-linked UHMWPE components was 0.5 +/- 0.7 mg/million cycles.

Metrology to quantify wear and creep of polyethylene tibial knee inserts.

Assessment of damage on articular surfaces of ultrahigh molecular weight polyethylene tibial knee inserts primarily has been limited to qualitative methods, such as visual observation and classification of features such as pitting, delamination, and subsurface cracking. Semiquantitative methods also have been proposed to determine the linear penetration and volume of the scar that forms on articular surfaces of tibial knee inserts. The current authors report a new metrologic method that uses a coordinate measuring machine to quantify the dimensions of this scar. The articular surface of the insert is digitized with the coordinate measuring machine before and after regular intervals of testing on a knee simulator. The volume and linear penetration of the scar are calculated by mathematically taking the difference between the digitized surface maps of the worn and unworn articular surfaces. Three conventional polyethylene tibial knee inserts of a posterior cruciate-sparing design were subjected to five million cycles of normal gait on a displacement-driven knee wear simulator in bovine serum. A metrologic method was used to calculate creep and wear contributions to the scar formation on each tibial plateau. Weight loss of the inserts was determined gravimetrically with the appropriate correction for fluid absorption. The total average wear volume was 43 +/- 9 and 41 +/- 4 mm3 measured by the metrologic and gravimetric methods, respectively. The wear rate averaged 8.3 +/- 0.9 and 8.5 +/- 1.6 mm3 per million cycles measured by the metrologic and gravimetric methods, respectively. These comparisons reflected strong agreement between the metrologic and gravimetric methods.

The use of trans-vinylene formation in quantifying the spatial distribution of electron beam penetration in polyethylene. Single-sided, double-sided and shielded irradiation.

The use of the quantification of trans-vinylene unsaturations in irradiated ultrahigh molecular weight polyethylene (UHMWPE) in determining the spatial distribution of electron beam penetration was investigated. UHMWPE was irradiated with a 10MeV linear electron beam accelerator to 100kGy at both room temperature and 125 degrees C in air. The irradiation was carried out in shielded and unshielded single-sided and unshielded double-sided irradiation modes. Dose-depth profiles were measured by quantifying the yields of trans-vinylene unsaturations as a function of depth away from the e-beam incidence surfaces using infrared spectroscopy. The extent of beam penetration increased with increasing irradiation temperature as was manifested by the increase in the iso-dose penetration with the unshielded single-sided irradiation and increased dose overlap with the unshielded double-sided irradiation. The optimum thickness with maximum uniformity in dose-depth distribution for double-sided irradiation was 85 and 90mm for 25 degrees C and 125 degrees C irradiation temperatures, respectively.

Aggressive wear testing of a cross-linked polyethylene in total knee arthroplasty.

Recently, highly cross-linked polyethylenes with high wear and oxidation resistance have been developed. These materials may improve the in vivo performance of polyethylene components used in total knee arthroplasty. To date, the in vitro knee wear testing of these new polyethylenes has been done under conditions of normal gait. However, their critical assessment also must include aggressive in vitro fatigue and wear testing. In the current study, an aggressive in vitro knee wear and device fatigue model simulating a tight posterior cruciate ligament balance during stair climbing was developed and used to assess the performance of one type of highly cross-linked polyethylene tibial knee insert in comparison with conventional polyethylene. The highly cross-linked inserts and one group of conventional inserts were tested after sterilization. One additional group of conventional inserts was subjected to accelerated aging before testing. The articular surfaces of the inserts were inspected visually for surface delamination, cracking, and pitting at regular intervals during the test. The aged conventional polyethylene inserts showed extensive delamination and cracking as early as 50,000 cycles. In contrast, the unaged conventional and highly cross-linked polyethylene inserts did not show any subsurface cracking or delamination at 0.5 million cycles. The appearance and location of delamination that occurred in the aged conventional inserts tested with the current model previously have been observed in vivo with posterior cruciate-sparing design knee arthroplasties with a tight posterior cruciate ligament.

Effects of femoral neck length, stem size, and body weight on strains in the proximal cement mantle.

BACKGROUND: Several studies have shown that certain cemented total hip replacement femoral stems have been associated with the complications of early debonding, loosening, and osteolysis. Some authors have suggested that these failures may be related to the surface finish of the stems. We developed an in vitro biomechanical experiment characterized by simulated stair-climbing to investigate the multiple factors involved in loosening of cemented femoral stems. In this study, we measured the effects of stem neck length, body weight, stem size, and calcar-collar contact on the torsional stability, as reflected by the strains in the proximal cement mantle, of one design of cemented femoral stem. METHODS: Eight Centralign femoral stems (Zimmer, Warsaw, Indiana) were cemented into eight cadaver femora with use of contemporary cementing techniques. Prior to insertion, fifteen strain-gauge rosettes were mounted around the proximal portion of the stem. The stems were loaded on a jig that simulated static peak loading during stair-climbing. Loading was repeated for each stem with three different joint reaction forces and for three different neck lengths. Calcar loading by the collar was then eliminated by removing a 0.5-mm slice of bone beneath the collar, and all loadings were then repeated. RESULTS: The peak principal tensile strains in the proximal cement increased linearly with both body weight (r (2) > 0.95) and neck length (r (2) > 0.75). Increasing body weight affected the peak cement strains far more than did increasing neck length. During simulated stair-climbing, calcar-collar contact reduced peak strains in the proximal cement by a factor of 1.5 to two. Peak principal tensile strains in the proximal cement often exceeded 1000 me when the smaller stems were used. CONCLUSIONS: In this stair-climbing test model, the peak proximal cement strains were increased more by changes in body weight than they were by changes in neck length. Even during stair-climbing, calcar-collar contact reduced peak cement strains.

Gradient crosslinking of UHMWPE using irradiation in molten state for total joint arthroplasty.

Increased crosslink density increases the wear resistance of ultra-high molecular weight polyethylene (UHMWPE) acetabular components used in total hip reconstructions. However, increasing crosslink density can reduce the mechanical properties of UHMWPE. Other researchers have tried to limit the crosslinking to a superficial layer on the articulating surfaces to retain the properties of the virgin polymer. We present here a method of producing a gradient of crosslink density across the acetabular component. Acetabular liners with 26 mm inner diameter were machined from the UHMWPE. The liners were then irradiated at 140 degrees C in the molten state of the polymer using a 2 MeV electron beam with limited penetration of the effects of radiation into polyethylene. The liners were then machined to an inner diameter of 32 mm to remove the radiation induced oxidized surface layer. The limited penetration of the e-beam resulted in a gradient of crosslink density with a crosslink density of 0.15 +/- 0.01 mol/dm3 near the articulating surfaces and 0.12 +/- 0.01 mol/dm3 near the backside. The concentration of the trans-vinylene unsaturations decreased gradually as a function of depth from the articulating surfaces to the backside of the liners. The wear resistance of the melt-irradiated liners was contrasted with those of conventional liners using the Boston hip simulator. The gravimetric wear rate was 27 +/- 5 mg million cycles with the conventional liners, while the melt-irradiated acetabular liners did not show any weight loss.