Structure, metallurgy, and mechanical properties of a porous tantalum foam.

This study evaluated a porous tantalum biomaterial (Hedrocel) designed to function as a scaffold for osseous ingrowth. Samples were characterized for structure, Vickers microhardness, compressive cantilever bending, and tensile properties, as well as compressive and cantilever bending fatigue. The structure consisted of regularly arranged cells having struts with a vitreous carbon core with layers of CVI deposited crystalline tantalum. Microhardness values ranged from 240-393, compressive strength was 60 +/- 18 MPa, tensile strength was 63 +/- 6 MPa, and bending strength was 110 +/- 14 MPa. The compressive fatigue endurance limit was 23 MPa at 5 x 10(6) cycles with samples exhibiting significant plastic deformation. SEM examination showed cracking at strut junctions 45 degrees to the axis of the applied load. The cantilever bending fatigue endurance limit was 35 MPa at 5 x 10(6) cycles, and SEM examination showed failure due to cracking of the struts on the tension side of the sample. While properties were variable due to morphology, results indicate that the material provides structural support while bone ingrowth is occurring. These findings, coupled with the superior biocompatibility of tantalum, makes the material a candidate for a number of clinical applications and warrants further and continued laboratory and clinical investigation.

Simulated knee wear with cobalt chromium and oxidized zirconium knee femoral components.

A knee simulator that mimics the plowing/rolling wear mechanisms of the knee was used to compare wear properties of cobalt chromium and oxidized zirconium femoral components. The simulator flexes and extends the knee so that the femoral components travels from 0 degrees to 30 degrees while applying axial loads from 130 to 1300 lb. Three oxidized zirconium and 3 cobalt chromium femoral components were tested with 10-mm tibial polyethylene components. The oxidized zirconium femoral components caused significantly less ultra high molecular weight polyethylene wear than cobalt chromium femoral components. Tibial inserts that were articulated against the cobalt chromium components had evidence of scratching, burnishing, and delamination, but none of the surfaces that were articulated against oxidized zirconium components had evidence of delamination. Cobalt chromium surface roughness significantly increased during the 2,000,000 cycle test, but oxidized zirconium surface roughness was not affected. Polyethylene wear was correlated to a significant degree with the surface roughness of the femoral components. The improved wear characteristics of the ceramic articular surfaces can be explained by the wettability of the ceramic surface, which minimized adhesive wear, and the resistance of the hard, ceramic surface to roughening.

Abrasive wear of ceramic, metal, and UHMWPE bearing surfaces from third-body bone, PMMA bone cement, and titanium debris.

The debris generated by the progressive wear of total joint replacement (TJR) devices is considered a primary cause of osteolysis, bone resorption, and premature failure of artificial hips and knees. The vast majority of this debris originates from the UHMWPE articulating surfaces caused by tribological interaction with the opposing metal or ceramic surface and hard particulates contained in the sinovial fluid. Entrapment of third body debris, such as cortical bone, PMMA cement, and titanium debris, between the articulating surfaces can cause abrasion of both the hard bearing surface and the UHMWPE. The propensity for abrasive wear is dependent on the relationship between the hardness of the third-body debris and the hardness of the bearing surfaces. To gain a better understanding of this relationship and its effect on wear, the abrasive wear behavior of several metal and ceramic bearing surfaces was characterized in terms of the hardness of both the third-body debris and the metal or ceramic substrate. The effects of abrasion and increased surface roughness of the metal or ceramic surfaces on wear of the UHMWPE was also determined. In addition, the amount of UHMWPE wear was quantified in terms of the amount (particles/ml) of titanium fretting-type debris contained in solution. The results of this investigation showed the resistance to abrasive wear of the metal and ceramic bearing surfaces to increase with increasing surface hardness. Bone debris, PMMA cement, and titanium debris produced visible abrasion of all metal surfaces including nitrogen ion implanted Ti-6Al-4V. The ceramic bearing surfaces showed no evidence of abrasion and produced the least amount of UHMWPE wear. The wear of UHMWPE sliding against Co-Cr-Mo was found to increase with increasing levels of 1.48 microns titanium debris added to the wear test solution. The rate of UHMWPE wear increased rapidly for concentrations of titanium debris in the test solution exceeding about 10(5) particles/ml. These test results suggest that third-body particles, both large and small, are capable of causing increased abrasive wear of UHMWPE, and that abrasion of the hard bearing surfaces will occur if the hardness of the third-body debris exceeds the hardness of the metal or ceramic bearing surface.

New surface-hardened, low-modulus, corrosion-resistant Ti-13Nb-13Zr alloy for total hip arthroplasty.

To optimize the performance of total hip replacement, scientists and clinicians are seeking new materials and noncemented, press-fit designs that can improve load transfer to the bone and reduce the incidence of loosening and thigh pain. Currently used Co-Cr-Mo alloy has a relatively high elastic modulus (E = 227 GPa), which limits its ability to transfer load to the surrounding bone in the proximal calcar region. Thus to improve load transfer, designs are considered with less cross-sectional area to increase flexibility, but at the expense of fit and fill, and thus stability of the implant within the bone. Should stem loosening occur, the stem stresses may exceed the relatively low fatigue strength of the Co-Cr-Mo alloy and lead to stem breakage. To improve these conditions, lower modulus Ti-6Al-4V alloy (E = 115 GPa) is being used. More recently, a new lower-modulus (E = 79 GPa) Ti-13Nb-13Zr alloy has been developed which does not contain any elemental constituents associated with adverse cell response (i.e., Co, Cr, Mo, Ni, Fe, Al, V), and which possesses comparable or superior strength and toughness to existing Ti-6Al-4V alloy. The carefully selected Nb and Zr constituents improve bone biocompatibility and corrosion resistance compared to that of currently used implant metals. Additionally, a unique diffusion hardening (DH) treatment can be conducted during the age-hardening process of this near-beta alloy to produce a hardened surface with abrasion resistance superior to that of Co-Cr-Mo alloy. This also provides an improvement in the micro-fretting tendencies that may occur within femoral head-neck taper regions and modular interfaces of other implant designs. The present study describes the metallurgy and mechanical properties of this unique low modulus Ti-13Nb-13Zr alloy, and the heat treatments used to obtain the high strength, corrosion resistance, and surface hardening that renders this biocompatible alloy well-suited for press fit hip replacement applications. Because of the relatively lower beta transus (735 degrees C), this alloy is also much easier to net shape forge into more complex stem designs.