Development of superlattice CrN/NbN coatings for joint replacements deposited by high power impulse magnetron sputtering.

The demand for reliable coating on medical implants is ever growing. In this research, enhanced performance of medical implants was achieved by a CrN/NbN coating, utilising nanoscale multilayer/superlattice structure. The advantages of the novel high power impulse magnetron sputtering technology, namely, its unique highly ionised plasma, were exploited to deposit dense and strongly adherent coatings on CoCr implants. Transmission electron microscopy analysis revealed coating superlattice structure with bi-layer thickness of 3.5 nm. CrN/NbN deposited on CoCr samples showed exceptionally high adhesion, critical load values of LC2 = 50 N in scratch adhesion tests. Nanoindentation tests showed high hardness of 34 GPa and Young's modulus of 447 GPa. Low coefficient of friction (µ) 0.49 and coating wear coefficient (K C) = 4.94 × 10(-16) m(3) N(-1) m(-1) were recorded in dry sliding tests. Metal ion release studies showed a reduction in Co, Cr and Mo release at physiological and elevated temperatures (70 °C) to almost undetectable levels (<1 ppb). Rotating beam fatigue testing showed a significant increase in fatigue strength from 349 ± 59 MPa (uncoated) to 539 ± 59 MPa (coated). In vitro biological testing has been performed in order to assess the safety of the coating in biological environment; cytotoxicity, genotoxicity and sensitisation testing have been performed, all showing no adverse effects.

The effects of manufacturing tolerances and assembly force on the volumetric wear at the taper junction in modular total hip arthroplasty.

Fretting and corrosion at the taper-head interface in total hip arthroplasty has been reported as a potential cause of early failure of the implant system. The finite element (FE) method can be used to study the mechanics at the taper junction that are difficult to assess experimentally. Taper mismatch is one of the factors that can influence the performance of the taper junction. In this study we have assessed the effect of taper mismatch, in combination with assembly force on the volumetric wear. The study showed that higher assembly forces and smaller mismatches result in the least volumetric wear.

A novel ceramic coating for reduced metal ion release in metal-on-metal hip surgery.

An ovine total hip arthroplasty model was developed to evaluate metal ion release, wear, the biological response and adverse tissue reaction to metal-on-metal (MoM) bearing materials. The performance of an advanced superlattice ceramic coating (SLC) was evaluated as a bearing surface and experimental groups divided into; (1) MoM articulating surfaces coated with a SLC coating (SLC-MoM), (2) uncoated MoM surfaces (MoM), and (3) metal on polyethylene (MoP) surfaces. Implants remained in vivo for 13 months and blood chromium (Cr) and cobalt (Co) metal ion levels were measured pre and postoperatively. Synovial tissue was graded using an ALVAL scoring system. When compared with the MoM group, sheep with SLC-MoM implants showed significantly lower levels of chromium and cobalt metal ions within blood over the 13-month period. Evidence of gray tissue staining was observed in the synovium of implants in the MOM group. A significantly lower ALVAL score was measured in the SLC-MoM group (3.88) when compared with MoM components (6.67) (p = 0.010). ALVAL results showed no significant difference when SLC-MOM components were compared to MoP (5.25). This model was able to distinguish wear and the effect of released debris between different bearing combinations and demonstrated the effect of a SLC coating when applied onto the bearing surface. © 2018 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater 107B: 1760-1771, 2019.

Finite element wear prediction using adaptive meshing at the modular taper interface of hip implants.

The use of modular components in total hip arthroplasty introduced an additional interface with the potential for fretting and corrosion to occur. Fretting and corrosion at this interface have been reported as a potential cause of early failure of the implant system. Using finite element (FE) analyses the mechanics at the taper junction can be studied. However, most FE studies are based on a single load condition and do not take geometry changes over time into account. Therefore, in this study an FE routine was developed, in which adaptations to the implant geometry are made to account for material removal during the fretting process. Material removal was simulated based on Archard's Law, incorporating contact pressure, micromotions and a wear factor which used input from in vitro fretting tests. A wear factor of 2.7*10-5mm3/Nmm was used to match the FE predicted volumetric wear to the measured experimental volumetric wear of 0.79mm3 after 10 million cycles. The maximum experimental wear depth found was 30.5 ± 17µm, while the FE predicted a maximum wear depth of 27µm. The adaptive meshing method has delivered results that are more similar to the experimental test data in comparison to the results from modelling a single cycle without adaptive meshing.

A combined experimental and finite element approach to analyse the fretting mechanism of the head-stem taper junction in total hip replacement.

Fretting corrosion at the taper interface of modular hip implants has been implicated as a possible cause of implant failure. This study was set up to gain more insight in the taper mechanics that lead to fretting corrosion. The objectives of this study therefore were (1) to select experimental loading conditions to reproduce clinically relevant fretting corrosion features observed in retrieved components, (2) to develop a finite element model consistent with the fretting experiments and (3) to apply more complicated loading conditions of activities of daily living to the finite element model to study the taper mechanics. The experiments showed similar wear patterns on the taper surface as observed in retrievals. The finite element wear score based on Archard's law did not correlate well with the amount of material loss measured in the experiments. However, similar patterns were observed between the simulated micromotions and the experimental wear measurements. Although the finite element model could not be validated, the loading conditions based on activities of daily living demonstrate the importance of assembly load on the wear potential. These findings suggest that finite element models that do not incorporate geometry updates to account for wear loss may not be appropriate to predict wear volumes of taper connections.

Topographical and chemical effects of electrochemically assisted deposited hydroxyapatite coatings on osteoblast-like cells.

A recently commercialised hydroxyapatite electrochemically assisted chemical deposition technique (BoneMaster) has been shown to induce increased bone apposition; whether this response is caused by the surface topography or chemistry is unknown. An in-vitro examination using human osteoblast-like cells was performed on a series of BoneMaster-coated surfaces. The chemistry was separated from the topography using a thin gold coating; Thermanox coverslips were used as a control. BoneMaster surfaces showed significantly greater alkaline phosphatase activity and osteocalcin production compared with controls; however, no difference was found between the gold-coated and uncoated BoneMaster samples, indicating topography is the main contributing factor.