Wave-Driven Assembly of Quasiperiodic Patterns of Particles.

We theoretically show that a superposition of plane waves causes small (compared to the wavelength) particles dispersed in a fluid to assemble in quasiperiodic two or three-dimensional patterns. We experimentally demonstrate this theory by using ultrasound waves to assemble quasiperiodic patterns of carbon nanoparticles in water using an octagonal arrangement of ultrasound transducers, and we document good agreement between theory and experiments. The theory also applies to obtaining quasiperiodic patterns in other situations where particles move with linear waves, such as optical lattices.

The Effect of Texture Floor Profile on the Lubricant Film Thickness in a Textured Hard-On-Soft Bearing With Relevance to Prosthetic Hip Implants.

Polyethylene wear debris limits the longevity of prosthetic hip implants. We design a pattern of axisymmetric texture features to increase hydrodynamic pressure and lubricant film thickness and, thus, reduce solid-on-solid contact, friction, and wear in hard-on-soft prosthetic hip implant bearings. Specifically, we study the effect of the texture floor profile on the lubricant film thickness using a soft elastohydrodynamic lubrication model. We compute the optimum texture parameters that maximize the lubricant film thickness for different texture floor profiles, as a function of bearing operating conditions. Flat texture floor profiles create thicker lubricant films than sloped or curved texture floor profiles for their respective optimum texture design parameters. We find that the texture feature volume is the most important parameter in terms of maximizing the lubricant film thickness, because a linear relationship exists between the texture feature volume with optimum texture parameters and the corresponding optimum lubricant film thickness, independent of the texture floor profile.

Surface Texturing of Prosthetic Hip Implant Bearing Surfaces: A Review.

More than 300,000 total hip replacement surgeries are performed in the United States each year to treat degenerative joint diseases that cause pain and disability. The statistical survivorship of these implants declines significantly after 15-25 years of use because wear debris causes inflammation, osteolysis, and mechanical instability of the implant. This limited longevity has unacceptable consequences, such as revision surgery to replace a worn implant, or surgery postponement, which leaves the patient in pain. Innovations such as highly cross-linked polyethylene and new materials and coatings for the femoral head have reduced wear significantly, but longevity remains an imminent problem. Another method to reduce wear is to add a patterned microtexture composed of micro-sized texture features to the smooth bearing surfaces. We critically review the literature on textured orthopedic biomaterial surfaces in the context of prosthetic hip implants. We discuss the different functions of texture features by highlighting experimental and simulated results documented by research groups active in this area. We also discuss and compare different manufacturing techniques to create texture features on orthopedic biomaterial surfaces and emphasize the key difficulties that must be overcome to produce textured prosthetic hip implants.

Maximizing the Lubricant Film Thickness Between a Rigid Microtextured and a Smooth Deformable Surface in Relative Motion, Using a Soft Elasto-Hydrodynamic Lubrication Model.

We design a pattern of microtexture features to increase hydrodynamic pressure and lubricant film thickness in a hard-on-soft bearing. We use a soft elastohydrodynamic lubrication model to evaluate the effect of microtexture design parameters and bearing operating conditions on the resulting lubricant film thickness and find that the maximum lubricant film thickness occurs with a texture density between 10% and 40% and texture aspect ratio between 1% and 14%, depending on the bearing load and operating conditions. We show that these results are similar to those of hydrodynamic textured bearing problems because the lubricant film thickness is almost independent of the stiffness of the bearing surfaces in full-film lubrication.

Polymer Spreading on Unidirectionally Nanotextured Substrates Using Molecular Dynamics.

A unidirectional nanotexture alters the wettability of a substrate and can be used to create patterned polymer films, tailored polymer coverage/reflow, or aligned polymer molecules. However, the physical mechanisms underlying polymer spreading on nanoscale textures are not well-understood, and competing theories exist to explain how texture peaks and grooves alter the wettability of a substrate. We use molecular dynamics to simulate polymer spreading on substrates with unidirectional nanoscale textures as a function of texture shape and size and compare to polymer spreading on a flat substrate. We show that the texture groove shape is the primary factor that modifies polymer spreading on unidirectionally nanotextured substrates because the texture groove shape determines the minimum potential energy of a substrate. At the texture groove, the energy potentials of several surfaces combine, which increases polymer attraction and drives spreading along the texture groove. A texture groove also acts as a sink that inhibits polymer spreading perpendicular to the texture. Texture peaks create energy barriers that inhibit polymer spreading perpendicular to the texture, but this is a secondary mechanism that does not significantly affect anisotropic spreading. This research unifies competing theories of anisotropic liquid spreading documented in the literature and aims to aid in the design of nanoscale textures and ultrathin liquid film systems.

Polymer spreading on substrates with nanoscale grooves using molecular dynamics.

Understanding how liquid polymer interacts with and spreads on surfaces with nanoscale texture features is crucial for designing complex nanoscale systems. We use molecular dynamics to simulate different types of polymer as they spread on substrates with a single nanoscale groove. We study how groove design affects the potential energy of a substrate and how this governs polymer spreading and orientation. Based on our simulations, we show that groove shape, polymer chemistry, and polymer molecule entanglement are the three parameters that determine polymer spreading on a nanoscale groove. We provide a molecular-level explanation of the underlying physical mechanisms, and we illustrate this fundamental understanding by designing a network of grooves to engineer user-specified polymer spreading and coverage. This work has implications for nanoscale systems and devices that involve the design of complex groove networks with an ultrathin polymer coating, including micro and nanoelectromechanical devices, nanoimprint lithography, flexible electronics, antibiofouling coatings, and hard disk drives.

Spreading Kinetics of Ultrathin Liquid Films Using Molecular Dynamics.

Ultrathin liquid films play a critical role in numerous engineering applications. Although crucial to the design and application of ultrathin liquid films, the physical mechanisms that govern spreading on the molecular scale are not well-understood, and disagreement among experiments, simulations, and theory remains. We use molecular dynamics simulations to quantify the speed at which the edge of a polymer droplet advances on a flat substrate as a function of various environmental and design parameters. We explain the physical mechanisms that drive and inhibit spreading, identify different spreading regimes, and clarify transitions between spreading regimes. We demonstrate that the edge of a droplet spreads according to a power law with two distinct regimes, which we attribute to competing physical mechanisms: a pressure difference in the liquid droplet and molecule entanglement. This research unifies many years of liquid spreading research and has implications for systems that involve designing complex ultrathin liquid films.

A patterned microtexture to reduce friction and increase longevity of prosthetic hip joints.

More than 285,000 total hip replacement surgeries are performed in the US each year. Most prosthetic hip joints consist of a cobalt-chromium (CoCr) femoral head that articulates with a polyethylene acetabular component, lubricated with synovial fluid. The statistical survivorship of these metal-on-polyethylene prosthetic hip joints declines significantly after 10 to 15 years of use, primarily as a result of polyethylene wear and wear debris incited disease. The current engineering paradigm to increase the longevity of prosthetic hip joints is to improve the mechanical properties of the polyethylene component, and to manufacture ultra-smooth articulating surfaces. In contrast, we show that adding a patterned microtexture to the ultra-smooth CoCr femoral head reduces friction when articulating with the polyethylene acetabular liner. The microtexture increases the load-carrying capacity and the thickness of the joint lubricant film, which reduces contact between the articulating surfaces. As a result, friction and wear is reduced. We have used a lubrication model to design the geometry of the patterned microtexture, and experimentally demonstrate reduced friction for the microtextured compared to conventional smooth surrogate prosthetic hip joints.

The accuracy of the compressible Reynolds equation for predicting the local pressure in gas-lubricated textured parallel slider bearings.

The validity of the compressible Reynolds equation to predict the local pressure in a gas-lubricated, textured parallel slider bearing is investigated. The local bearing pressure is numerically simulated using the Reynolds equation and the Navier-Stokes equations for different texture geometries and operating conditions. The respective results are compared and the simplifying assumptions inherent in the application of the Reynolds equation are quantitatively evaluated. The deviation between the local bearing pressure obtained with the Reynolds equation and the Navier-Stokes equations increases with increasing texture aspect ratio, because a significant cross-film pressure gradient and a large velocity gradient in the sliding direction develop in the lubricant film. Inertia is found to be negligible throughout this study.

Designing prosthetic knee joints with bio-inspired bearing surfaces.

It has long been known that articular cartilage exhibits a surface microtexture with shallow indentations. By contrast, prosthetic joints consist of ultra-smooth bearing surfaces, the longevity of which does not reach that of natural cartilage. We show that adding a microtexture to the smooth femoral component of a prosthetic knee joint reduces friction by increasing the lubricant film thickness between the bearing surfaces of the knee. We have implemented an elastohydrodynamic lubrication model to optimize the geometry of the microtexture, while taking into account the deformation of the polyethylene tibial insert. We have manufactured several microtexture designs on a surrogate femoral component, and experimentally demonstrate that the microtexture reduces friction between the surrogate femoral component and tibial insert.

A data-driven approach to the "Everesting" cycling challenge.

The "Everesting" challenge is a cycling activity in which a cyclist repeats a hill until accumulating an elevation gain equal to the elevation of Mount Everest in a single ride. The challenge experienced a surge in interest during the COVID-19 pandemic and the cancelation of cycling races around the world that prompted cyclists to pursue alternative, individual activities. The time to complete the Everesting challenge depends on the fitness and talent of the cyclist, but also on the length and gradient of the hill, among other parameters. Hence, preparing an Everesting attempt requires understanding the relationship between the Everesting parameters and the time to complete the challenge. We use web-scraping to compile a database of publicly available Everesting attempts, and we quantify and rank the parameters that determine the time to complete the challenge. We also use unsupervised machine learning algorithms to segment cyclists into distinct groups according to their characteristics and performance. We conclude that the power per unit body mass of the cyclist and the tradeoff between the gradient of the hill and the distance are the most important considerations when attempting the Everesting challenge. As such, elite cyclists best select a hill with gradient > 12%, whereas amateur and recreational cyclists best select a hill with gradient < 10% to minimize the time to complete the Everesting challenge.

An experimental approach to determining fatigue crack size in polyethylene tibial inserts.

A major limiting factor to the longevity of prosthetic knee joints is fatigue crack damage of the polyethylene tibial insert. Existing methods to quantify fatigue crack damage have several shortcomings, including limited resolution, destructive testing approach, and high cost. We propose an alternative fatigue crack damage visualization and measurement method that addresses the shortcomings of existing methods. This new method is based on trans-illumination and differs from previously described methods in its ability to non-destructively measure subsurface fatigue crack damage while using a simple and cost-effective bench-top set-up. We have evaluated this method to measure fatigue crack damage in two tibial inserts. This new method improves on existing image-based techniques due to its usability for subsurface damage measurement and its decreased reliance on subjective damage identification and measurement.

Using a surrogate contact pair to evaluate polyethylene wear in prosthetic knee joints.

With recent improvements to the properties of ultra-high molecular weight polyethylene (UHMWPE) used in joint replacements, prosthetic knee and hip longevity may extend beyond two decades. However, it is difficult and costly to replicate such a long in vivo lifetime using clinically relevant in vitro wear testing approaches such as walking gait joint simulators. We advance a wear test intermediate in complexity between pin-on-disk and knee joint simulator tests. The test uses a surrogate contact pair, consisting of a surrogate femoral and tibial specimen that replicate the contact mechanics of any full-scale knee condyle contact pair. The method is implemented in a standard multi-directional pin-on-disk wear test machine, and we demonstrate its application via a two-million-cycle wear test of three different UHMWPE formulations. Further, we demonstrate the use of digital photography and image processing to accurately quantify fatigue damage based on the reduced transmission of light through a damage area in a UHMWPE specimen. The surrogate contact pairs replicate the knee condyle contact areas within -3% to +12%. The gravimetric wear test results reflect the dose of crosslinking radiation applied to the UHMWPE: 35 kGy yielded a wear rate of 7.4 mg/Mcycles, 55 kGy yielded 1.0 mg/Mcycles, and 75 kGy (applied to a 0.1% vitamin E stabilized UHMWPE) yielded 1.5 mg/Mcycles. A precursor to spalling fatigue is observed and precisely measured in the radiation-sterilized (35 kGy) and aged UHMWPE specimen. The presented techniques can be used to evaluate the high-cycle fatigue performance of arbitrary knee condyle contact pairs under design-specific contact stresses, using existing wear test machines. This makes the techniques more economical and well-suited to standardized comparative testing.

The effect of polyethylene creep on tibial insert locking screw loosening and back-out in prosthetic knee joints.

A prosthetic knee joint typically comprises a cobalt-chromium femoral component that articulates with a polyethylene tibial insert. A locking screw may be used to prevent micromotion and dislodgement of the tibial insert from the tibial tray. Screw loosening and back-out have been reported, but the mechanism that causes screw loosening is currently not well understood. In this paper, we experimentally evaluate the effect of polyethylene creep on the preload of the locking screw. We find that the preload decreases significantly as a result of polyethylene creep, which reduces the torque required to loosen the locking screw. The torque applied to the tibial insert due to internal/external rotation within the knee joint during gait could thus drive locking screw loosening and back-out. The results are very similar for different types of polyethylene.

Creating a collimated ultrasound beam in highly attenuating fluids.

We have devised a method, based on a parametric array concept, to create a low-frequency (300-500 kHz) collimated ultrasound beam in fluids highly attenuating to sound. This collimated beam serves as the basis for designing an ultrasound visualization system that can be used in the oil exploration industry for down-hole imaging in drilling fluids. We present the results of two different approaches to generating a collimated beam in three types of highly attenuating drilling mud. In the first approach, the drilling mud itself was used as a nonlinear mixing medium to create a parametric array. However, the short absorption length in mud limits the mixing length and, consequently, the resulting beam is weak and broad. In the second improved approach, the beam generation process was confined to a separate "frequency mixing tube" that contained an acoustically non-linear, low attenuation medium (e.g., water) that allowed establishing a usable parametric array in the mixing tube. A low-frequency collimated beam was thus created prior to its propagation into the drilling fluid. Using the latter technique, the penetration depth of the low frequency ultrasound beam in the drilling fluid was significantly extended. We also present measurements of acoustic nonlinearity in various types of drilling mud.