Evaluation of Mechanically-Assisted Crevice Corrosion of Different Modular Dual Mobility Constructs.

BACKGROUND: Modular dual mobility (MDM) acetabular component use is rising in total hip arthroplasty. However, concern of mechanically assisted crevice corrosion (MACC) at the shell-liner interface remains. We investigated shell-liner corrosion using retrieval analyses and corrosion chamber testing. METHODS: We analyzed fretting and corrosion on 10 matched pairs of 2 commercial MDM constructs (MDM1 and MDM2). Also, pristine pairs of Ti6Al4V shells and CoCrMo liners from 3 commercial dual mobility systems (MDM1, MDM2, and MDM3) were tested in vitro to model MACC performance. Three pairs of each were placed into an electrochemical chamber with stepwise increasing cyclic compression loads while measuring currents generated at the shell-liner taper. Onset fretting loads and fretting currents were calculated. RESULTS: Corrosion damage scores on retrieved components were low but higher in the MDM2 to MDM1 liners (P = .006), specifically outside the taper region (P = .00003). Fretting currents were higher in the MDM2 than in MDM1 or MDM3 (P = .011). Onset loads were also higher in the MDM2 (P = .001). CONCLUSION: Among retrieved liners, MDM2 tapers seem prone to non-mechanical corrosion modes. Higher onset loads and fretting currents in MDM2 tapers indicate greater MACC resistance but higher severity once corrosion begins. Differences among the devices were likely due to taper design and surface finish. Currents in all 3 were <5 µA, much lower than those observed with head-neck tapers. Our findings suggest that, among the types of corrosion observed in these MDM designs, mechanically driven corrosion may not be the most significant.

Clinical and Biomechanical Characteristics of Posterior-Stabilized Polyethylene Post Fractures in Total Knee Arthroplasty: A Retrieval Analysis.

BACKGROUND: Fractures of the polyethylene post are a rare but known complication after posterior-stabilized (PS) total knee arthroplasty (TKA). We evaluated the polyethylene and patient characteristics for 33 primary PS polyethylene components that were revised with fractured posts. METHODS: We identified 33 PS inserts revised between 2015 and 2022. Patient characteristics collected included age at index TKA, sex, body mass index, length of implantation (LOI), and patient-reported details on events surrounding the post fracture. Implant characteristics recorded were manufacturer, cross-linking properties (highly cross-linked polyethylene [XLPE] versus ultra-high molecular weight polyethylene [UHMWPE]), wear characteristics based on subjective scoring of the articular surfaces and scanning electron microscopy (SEM) of fracture surfaces. Mean age at index surgery was 55 years (range, 35 to 69), mean body mass index was 29.5 (range, 18.5 to 37.2), and mean LOI was 10.0 (range, 4 to 26). RESULTS: Total surface damage scores were significantly higher in the UHMWPE group versus the XLPE group (57.3 versus 44.2, P = .003). SEM demonstrated fracture initiation at the posterior edge of the post in 10 of 13 cases. UHMWPE fracture surfaces posts had more tufted, irregularly clamshell features, while XLPE posts had more precise clamshell marking and a diamond pattern in the region of acute, final fracture. CONCLUSION: Characteristics of PS post fracture differed between XLPE and UHMWPE implants, with fractures occurring in the XLPE with less generalized surface damage, after a shorter LOI, and with SEM evaluation indicative of a more brittle fracture pattern.

Nontribological corrosion modes dominate wrought CoCrMo acetabular taper corrosion: A retrieval study.

Corrosion of modular metal-on-metal acetabular tapers in total hip arthroplasty (THA) systems is often attributed to mechanically driven processes. Recent findings suggest that mechanically assisted crevice corrosion (MACC) might not be the dominant cause of corrosion in shell-liner tapers. This study aims to document and present the corrosion modes observed in metal-metal acetabular liners. Twenty-one retrieved wrought CoCrMo liners were examined using digital optical microscopy (DOM), scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS). Corrosion-related damage was documented in nonengagement taper regions, outside of direct taper contact. Within engagement regions, nonmechanically driven corrosion features (pitting, intergranular corrosion) were observed adjacent to fretting and material transfer, which rely on mechanical contact; corrosion independent of MACC was observed even in contact regions. Corrosion types observed included intergranular corrosion (IGC), pitting attack, phase boundary dissolution, all both outside and inside of taper junctions, and MACC within contact regions of the taper. Typical fretting scars associated with MACC were mostly absent, and were not always associated with corrosion damage where present. Finally, hard phase particles (Mo-Si-O) released from the wrought CoCrMo microstructure had redeposited within regions with material loss. Acetabular taper corrosion modes differ significantly from those in head-neck tapers and are dominated by electrochemically driven processes, not mechanical processes, as indicated by corrosion in noncontact regions. With greater prevalence of dual mobility hip implants, acetabular taper corrosion processes must be understood in order to limit their impact on device performance.

Sensing Localized Surface Corrosion Damage of CoCrMo Alloys and Modular Tapers of Total Hip Retrievals Using Nearfield Electrochemical Impedance Spectroscopy.

Wear and corrosion damage of biomedical alloys alters the structure and electrochemical properties of the surface heterogeneously. It was hypothesized that local regions on the same surface systematically differ from one another in terms of their impedance characteristics. To test this hypothesis, CoCrMo disks exposed to electrosurgical and inflammatory-species-driven damage were characterized using a localized impedance technique, nearfield electrochemical impedance spectroscopy (NEIS), to assess point-specific surface integrity in response to applied damage. It was found that electrosurgical damage, as may arise during primary arthroplasty and revision surgeries, and hydrogen peroxide concentrations of 5-10 mM significantly alter the corrosion susceptibility of the local surface compared to the as-polished CoCrMo surface. A CoCrMo retrieved neck taper (Goldberg score of 4) was scored in different local regions on the basis of visual appearance, and it was found that there is a direct relationship between increasing debris coverage and decreasing impedance, with the global surface impedance closest to the most severely scored local region. This noninvasive method, which uses a millielectrode configuration to test localized regions, can measure the heterogeneous electrochemical impedance of an implant surface and be tailored to assess specific damage and corrosion mechanisms revealed on retrieval surfaces.

In vitro test methods for seating and fretting corrosion behavior of modular metal-on-metal acetabular tapers.

Retrieval studies show that metal-on-metal acetabular shell-liner tapers are susceptible to corrosion, which is hypothesized to arise from mechanically-assisted crevice corrosion (MACC). The role of materials on MACC of acetabular tapers has not been previously studied. In vitro tests of seating, pushout, and fretting corrosion performance of acetabular tapers are presented to assess the role of material combinations (Ti-6Al-4V shells, HC CoCrMo, LC CoCrMo, and 316L SS liners). The acetabular tapers were wet-assembled to a seating load of 1,000 N. The liner load-displacement seating mechanics were measured. Fretting corrosion currents were evaluated using a uniaxial incremental cyclic compression test up to 4,000 N, with the load applied at a 55° angle to the taper interface. Fretting currents, fretting onset loads, taper disengagement strength were measured and load-displacement plots were obtained. Pushout tests were also performed pre- and post-fretting corrosion. The average liner seating displacements varied from 134 to 226 µm across groups. Fretting currents at 3,600 N cyclic load were low and ranged between 0.05 and 0.27 µA and were independent of material combination (p > 0.05), reflecting small amounts of fretting. Fretting corrosion onset loads were between 1,800 and 2,100 N, and did not differ across groups (p > 0.05). Pushout loads were 27-43% of the maximum load applied. Fretting corrosion levels were very low for all material combinations and not different from one another. The seating and pushout responses were also not material dependent. The low fretting currents measured imply that MACC may not be a major cause for acetabular taper corrosion. © 2019 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 38:00-111089, 2020.

The seating mechanics of head-neck modular tapers in vitro: Load-displacement measurements, moisture, and rate effects.

The mechanically assisted crevice corrosion performance of head-neck modular tapers is a significant concern in orthopedic biomaterials. Fretting crevice corrosion processes in modular tapers are thought to be influenced by a wide array of factors including seating mechanics of the junction, hence there is a need for in vitro test methods that can assess their performance. This study presented a test method to directly measure the load-displacement seating mechanics of modular tapers and used this method to compare the seating mechanics for different tapers, moisture, seating loads and seating rates. Seating mechanics were explored whereby the instantaneous load-displacement behavior of the head seating onto the neck is captured and used to define the mechanics of seating. Two distinct taper design/material combinations were assembled wet or dry using axially applied loads (500, 1,000, 2,000, and 4,000 N) at two loading rates of 100 and 104 N/s (n = 5 for each condition) using a servohydraulic test frame. The results showed that pull-off strength scaled with seating load and ranged between 43% and 68% of seating load depending on sample and wetness. Tapers seated wet had higher pull-off strengths (2,200 ± 300 N) than those seated dry (1,800 ± 200 N, p < 0.05). Seating mechanics (load-displacement plots) varied due to sample type and due to wetness with differences in seating energy, seating stiffness, and seating displacement. These results show the detailed mechanics of seating during assembly and provide significant insight into the complex interplay of factors associated with even "ideal" seating (axial, quasistatic) loading. © 2017 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 36:1164-1172, 2018.