Microwear phenomena of ultrahigh molecular weight polyethylene cups and debris morphology related to gamma radiation dose in simulator study.

Ultrahigh molecular weight polyethylene (PE) cups with 0, 2.5, 50, 100, and 150 Mrad radiation treatments were run in a hip simulator for comparison of the microwear phenomena on the cup surfaces with the corresponding debris morphology. In general, the size and frequency of the PE surface fibrils and the size of the retrieved PE debris decreased with increasing radiation dose. The fibril size and shape on the cup surfaces were well correlated with the radiation dose. The fibrillar shape and size were found to be proportional to the square root of the radiation dose. However, the trend for size and shape factors of the wear debris related to the radiation dose was weak at best. Thus, the morphology of the PE fibrils on the cup surfaces was more sensitive to variations in the radiation dose than the actual wear debris. The wear response appeared to be a three-step process, which was dependent on the formation of surface nodules or ripples, the teasing out of surface fibrils, and the toughness of the PE matrix in releasing a wear fibril to form a debris particle. The tougher PE became with increasing radiation dose, the harder it was for the PE fibrils to break out into wear particles.

Effects of A-P translation and rotation on the wear of UHMWPE in a total knee joint simulator.

We developed a three-channel total knee joint simulator and studied the effect of tibial anterior-posterior translation and internal/external rotation on the wear of polyethylene tibial inserts in total knee replacements (Anatomic Graduated Component knees). The wear rate was the lowest in experiment (Exp.) 1, without translation and rotation [1.74 mg/million (mg/Mc) cycles]. In Exp. 2, with +/-5 degrees tibial rotation added, the wear rate increased to 10.6 mg/Mc. In Exp. 3, with rotation and -12 mm tibial translation added, the wear rate was 15.1 mg/Mc, whereas in Exp. 4, with rotation and +12 mm tibial translation, the wear rate was 18.7 mg/Mc. Internal/external rotation and anterior-posterior translation added a 6- to 11-fold increase in the wear rates of tibial knee inserts. The shapes of the tibial wear tracks were rectangular and the area of the track increased when rotation and translation were added.

Wear of ultra-high molecular weight polyethylene and polytetrafluoroethylene in a hip simulator: a dose-response study of protein concentration.

Charnley's laboratory wear studies of non-gamma sterilized polytetrafluoroethylene (PTFE) and polyethylene (PE) found that the PTFE to PE wear-rate ratio of 250:1 was much higher than the in-vivo wear ratio of 20:1. Tests of PTFE and PE in our laboratory showed a wear ratio of 150:1, using bovine serum as the lubricant and 190:1 with water as the lubricant. Our hypothesis was that the wear-rates of PTFE and PE cup materials were related to the concentration of protein in the serum. We studied the wear behavior of PTFE and PE cups in varied protein concentrations, using 4 femoral head sizes to validate the clinical range reported by Charnley. The PTFE wear-rates increased with increasing protein concentration and conversely, PE wear-rates decreased with increasing protein concentration. This inverse relationship made it possible to bring the wear ratio closer to the desired clinical wear ratio. We found that the clinically relevant PTFE/PE wear ratio corresponded to 3-10 mg/mL of protein in bovine serum.

Water and bovine serum lubrication compared in simulator PTFE/CoCr wear model.

Controversy surrounds wear data from laboratory hip simulator studies, whether derived from water-based or serum-based studies or whether a major design parameter such as the size of the femoral head has an effect on the volume of wear particulate released. To investigate these relationships, we studied cup wear in water- and serum-based lubricants using as our standard the polytetrafluoroethylene (PTFE) data derived by Charnley. To model Charnley's clinical experience, PTFE acetabular cups were used in sets of three each of four sizes of CoCr femoral heads: 22.25-, 28-, 32-, and 42-mm diameters. Six criteria were used to evaluate the performance of the lubricants against clinical accuracy and scientific methods. The PTFE wear data from the serum-based tests was consistently linear with the duration of the test, exhibited a precision within +/-3% about the average for each set of three cups, and copious amounts of wear debris were clearly seen circulating and settling to the bottom of the wear chambers. The wear data clearly demonstrated Charnley's thesis that volume of wear increases with regard to the size of the femoral head in a linear manner. This increase was considered satisfactory at 9%/ mm. However, in terms of clinical accuracy, the simulator wear rates averaged 3 to 4 times greater than the comparable clinical data for wear magnitude. Thus, the serum-based tests satisfied three of the six criteria used. The PTFE wear data from the water-based tests was generally nonlinear, continually increasing with test duration. These wear trends were examined in three discrete phases to estimate the changing wear rates. By the end of the tests, the wear rates had increased from 1.3 to 3.9 times, with the 42-mm heads showing the greatest change. The resulting precision was never better than +/-26% and deteriorated to +/-70%. In terms of clinical accuracy, the water-based wear rates varied from 2 to 7 times less than the Charnley PTFE wear magnitudes, averaging 4 times less. The water-based data did not satisfactorily model the relationship between increased wear with increased head size. Minimal PTFE wear debris was observed, and what did emerge after thousands of wear cycles appeared as streamers up to 30 mm long and up to 5 mm wide. When these detached, they floated up to the surface where they could be separated into smaller particulates. A similar phenomenon was noted for polyethylene wear tests conducted with water lubrication. Thus the water-based tests satisfied none of the six validation criteria evaluated. These data raise serious doubts as to the validity of testing implant and material combinations in water as a predictor of clinical performance. Bovine serum was not totally satisfactory, but the wear data did model some of the important clinical characteristics of hip joint behavior.