Corrosion on the acetabular liner taper from retrieved modular metal-on-metal total hip replacements.

Eight retrieved metal-on-metal total hip replacements displayed corrosion damage along the cobalt-chromium alloy liner taper junction with the Ti alloy acetabular shell. Scanning electron microscopy indicated the primary mechanism of corrosion to be grain boundary and associated crevice corrosion, which was likely accelerated through mechanical micromotion and galvanic corrosion resulting from dissimilar alloys. Coordinate measurements revealed up to 4.3mm(3) of the cobalt-chromium alloy taper surface was removed due to corrosion, which is comparable to previous reports of corrosion damage on head-neck tapers. The acetabular liner-shell taper appears to be an additional source of metal corrosion products in modular total hip replacements. Patients with these prostheses should be closely monitored for signs of adverse reaction towards corrosion by-products.

The influence of head size on corrosion and fretting behaviour at the head-neck interface of artificial hip joints.

The primary goal of this study was to determine if head size affects corrosion and fretting behaviour at the head-neck taper interface of modular hip prostheses. Seventy-four implants were retrieved that featured either a 28 mm or a 36 mm head with a metal-on-polyethylene articulation. The bore of the heads and the neck of the stems were divided into eight regions each and graded by three observers for corrosion and fretting damage separately using modified criteria as reported in the literature. The 36 mm head size featured a significant difference in the corrosion head scores (p=0.022) in comparison to the 28 mm heads. This may be attributed to a greater torque acting along the taper interface due to activities of daily living.

Abrasive wear and metallosis associated with cross-linked polyethylene in total hip arthroplasty.

A 34-year-old female patient received a cobalt-chromium (CoCr) alloy femoral head on cross-linked polyethylene total hip replacement for the revision of her fractured ceramic-on-ceramic total hip replacement. The CoCr alloy femoral head became severely worn due to third-body abrasive wear by ceramic particles that could not be removed by synovectomy or irrigation at revision surgery. Ceramic particles were found embedded in the cross-linked polyethylene liner. The CoCr alloy femoral head exhibited a total mass loss of 14.2 g and the generated wear particles triggered metallosis in the patient. The present case study suggests not revising a fractured ceramic-on-ceramic total hip replacement with a CoCr alloy femoral head and a cross-linked polyethylene liner to avoid metallosis due to third-body abrasive wear.

Prediction of backside micromotion in total knee replacements by finite element simulation.

The micromotion at the interface between the polyethylene tibial insert and metal tibial tray [corrected] in modular total knee replacements [corrected] has been shown to contribute to wear particle-induced osteolysis and may [corrected] cause implant failure. Therefore, studying the design parameters that are involved in the backside wear process is an important task that may lead to improvement in new total knee replacements. In the present study, a finite element model was developed to predict the backside micromotion along the entire modular interface. Both the linear elastic constitutive model and non-linear J2-plasticity constitutive model were considered in the finite element model for polyethylene and were corroborated against published results obtained from displacement controlled knee simulator wear tests. The finite element simulation with the non-linear J2-plasticity constitutive model was able to predict backside micromotion [corrected] more accurately than the simulation with the linear elastic constitutive model. [corrected] The developed finite element model (including the non-linear J2-plasticity constitutive model) was then applied to assess the effects of the tibial tray locking mechanism design (dovetails versus fullperipheral [corrected] design) and different levels of interference fit on insert micromotion. The developed finite element model, implementing the non-linear J2-plasticity constitutive model, was shown to successfully predict clinical amounts of backside micromotion and could be used for the design and development of total knee replacements for the reduction of backside micromotion and polyethylene [corrected] wear.

Calf serum constituent fractions influence polyethylene wear and microbial growth in knee simulator testing.

Calf serum lubricants consisting of various polypeptide constituent fractions are routinely used in knee wear simulators as part of the standardized test protocol. Three calf sera (bovine, new-born and alpha) were diluted as per the recommendation of ISO 14243-3 and used in displacement-controlled knee wear simulators to investigate their effects on polyethylene wear. Biochemical analyses included measuring total polypeptide degradation, electrophoretic profiles and low-molecular weight polypeptide concentrations to elucidate their involvement in the wear process. The effects of the various calf sera constituent fractions on microbial growth were also explored. The polyethylene wear rates and the results from the biochemical analyses for the three calf serum lubricants were all found to be statistically significantly different from each other. The lubricant derived from the alpha-calf serum was closest in constituent fractions to human synovial fluid. It also showed the lowest polyethylene wear rate (14.38 +/- 0.85 mm3/million cycles) and the lowest amount of polypeptide degradation (7.77 +/- 3.87%). Furthermore, the alpha-calf serum lubricant was associated with the least amount of change in the electrophoretic profile, the least change in low-molecular weight polypeptide concentration, and the lowest microbial growth in the presence of sodium azide (a microbial inhibitor conventionally used in implant wear testing). Replacing sodium azide with a broad spectrum antibiotic-antimycotic eradicated the microbial growth. Some speculation was entertained regarding the effect of alpha-calf serum on colloid-mediated boundary lubrication. Based on the results, it was recommended that ISO 14243-3 be modified to include guidelines on calf serum constituent fractions that would favour using alpha-calf serum in order to improve the fidelity of the simulation in knee implant wear testing.

Measurements of surface and subsurface damage in retrieved polyethylene tibial inserts of a contemporary design.

In the present study, surface and subsurface damage due to wear and creep in retrieved tibial inserts from the Genesis II total knee replacement (Smith & Nephew, Memphis, TN) are quantified. The utility of a number of recently validated micro-computed tomography (micro-CT) techniques for use in retrieval studies are also demonstrated. Sixteen inserts retrieved from patients after an implantation time from 0.5 to 86 months were examined. The inserts were scanned using micro-CT, and the three-dimensional surface deviations (corresponding to wear and creep) between the retrieved inserts and a reference geometry were determined. The subsurface of the inserts was also examined. Deviations within damage features were measured, and a surface deviation rate (mm/ year) was calculated from the length of implantation. No subsurface fatigue damage was found. The mean deviation within the most damaged regions of the articular surface was 0.115 ± 0.064 mm medially and 0.099 ± 0.061 mm laterally (p = 0.20). The mean articular deviation rate for inserts in vivo for more than 1 year was 0.049 mm/year and was reduced to 0.026 mm/year in inserts implanted for more than 4 years. Wear and creep of the Genesis II PE insert was comparable to reported values in other total knee replacements.

In vitro quantification of wear in tibial inserts using microcomputed tomography.

BACKGROUND: Wear of polyethylene tibial inserts can decrease the longevity of total knee arthroplasty. Wear is currently assessed using laboratory methods that may not permit backside wear measurements or do not quantify surface deviation. QUESTIONS/PURPOSES: We developed and validated a technique to quantify polyethylene wear in tibial inserts using microcomputed tomography (micro-CT), a nondestructive high-resolution imaging technique that provides detailed images of surface geometry in addition to volumetric measurements. METHODS: Six unworn and six wear-simulated polyethylene tibial inserts were evaluated. Each insert was scanned three times using micro-CT at a resolution of 50 µm. The insert surface was reconstructed for each scan and the insert volume was calculated. Gravimetric analysis was performed for all inserts, and the micro-CT and gravimetric volumes were compared to determine accuracy. We created three-dimensional surface deviation maps. RESULTS: Micro-CT generated high-quality three-dimensional renderings of the insert surface geometry. Between-scan precision was 0.07%; we observed no difference between micro-CT and gravimetric volume measurements. CONCLUSIONS: Micro-CT can provide precise and accurate volumetric measurements in addition to quantifiable three-dimensional surface deviation maps for the entire insert surface. The technique has the potential to evaluate wear in wear simulator trials and retrieval studies. CLINICAL RELEVANCE: This micro-CT technique combines the benefits of volumetric and surface scanning methods to quantify wear across all surfaces of polyethylene components with a single tool. When applied in wear simulator and retrieval studies, these measurements can be used to evaluate and predict the wear properties of the components.

Posterior condyle surface damage on retrieved femoral knee components.

Twenty-two retrieved femoral knee components were identified with posterior condyle surface damage on average at 99° flexion (range, 43°-135° flexion). Titanium alloy material transfer and abrasive surface damage were evident on cobalt-chromium alloy femoral components that were in contact with titanium alloy tibial trays. Surface damage on the retrieved Oxinium femoral components (Smith and Nephew, Inc, Memphis, Tenn) that were in contact with titanium alloy tibial trays showed gouging, associated with the removal and cracking of the oxide and exposure of the zirconium-niobium alloy substrate. Cobalt-chromium alloy femoral components that were in contact with cobalt-chromium alloy tibial trays showed abrasive wear. Contact between the femoral component and tibial tray should be avoided to prevent surface damage to the femoral condyles, which could potentially accelerate polyethylene wear in vivo.

The biochemical characteristics of wear testing lubricants affect polyethylene wear in orthopaedic pin-on-disc testing.

Lubricant protein concentration is known to affect crosslinked polyethylene wear in in vitro testing; however, the biochemical nature of these lubricants may also have a significant effect on wear and dictate its clinical relevance. A modified approach to pin-on-disc testing was implemented to explore the effect of four biochemically different lubricants on the wear of two types of crosslinked polyethylene materials (XLK™ and Marathon™; DePuy Synthes, Warsaw, IN, USA). XLK was associated with higher wear rates than Marathon. In comparison to lubricants containing deionized water, lubricants containing phosphate buffered saline solution and hyaluronic acid increased osmolality by up to 1.2 times and thermal stability by up to 1.4 times. This biochemical change reduced wear by up to 12.5 times. Wear rates for XLK and Marathon differed by a factor of 3.2 using lubricants with phosphate buffered saline solution as the dilutive media, but only 2.0 for lubricants with deionized water. Interestingly, varying the concentration of hyaluronic acid did not have a significant effect on wear, and differences between XLK and Marathon wear rates were not found to be statistically significant when hyaluronic acid was added to the lubricant. The findings of this study showed that increasing the osmolality and thermal stability of lubricants to more clinical levels decreased wear; however, the effect of hyaluronic acid on wear may not be apparent in simplistic pin-on-disc testing. It was suggested that phosphate buffered saline solution be used as the dilutive media of choice in order to better differentiate the ranking of materials while maintaining some clinical relevance.

An energy dissipation and cross shear time dependent computational wear model for the analysis of polyethylene wear in total knee replacements.

The cost and time efficiency of computational polyethylene wear simulations may enable the optimization of total knee replacements for the reduction of polyethylene wear. The present study proposes an energy dissipation wear model for polyethylene which considers the time dependent molecular behavior of polyethylene, aspects of tractive rolling and contact pressure. This time dependent - energy dissipation wear model was evaluated, along with several other wear models, by comparison to pin-on-disk results, knee simulator wear test results under various kinematic conditions and knee simulator wear test results that were performed following the ISO 14243-3 standard. The proposed time dependent - energy dissipation wear model resulted in improved accuracy for the prediction of pin-on-disk and knee simulator wear test results compared with several previously published wear models.

Biochemical analyses of human osteoarthritic and periprosthetic synovial fluid.

Biochemical analyses were performed on osteoarthritic and periprosthetic synovial fluid in order to propose changes to lubricant specifications currently outlined in orthopaedic wear testing standards. Osteoarthritic and periprosthetic synovial fluid samples were obtained from the hip and knee joints of 40 patients. The samples in each group were analysed and compared in order to identify differences between the protein concentration, constituent fractions, osmolality, thermal stability and the hyaluronic acid concentration and molecular weight distribution of osteoarthritic and periprosthetic synovial fluid. The average total protein concentration was approximately 30 g/L, which was much higher than the 20 g/L currently specified in the knee wear testing standard; however, the 30 g/L protein concentration matched the recently revised standard for hip simulator wear testing. No significant difference was found between the protein concentration, osmolality, thermal stability, and hyaluronic acid concentration of osteoarthritic and periprosthetic synovial fluid. The clinical data provided should be used to better define the composition of a more clinically relevant lubricant for orthopaedic wear testing.

Clinical failure analysis of contemporary ceramic-on-ceramic total hip replacements.

The present study investigates the performance of ceramic-on-ceramic total hip replacements by combining a retrieval analysis with a survivorship analysis to elucidate mechanisms that led to clinical failure. Semiquantitative surface damage assessment, contact profilometry, contour measurements, and scanning electron microscopy were performed to characterize the types and quantify the extent of surface damage on the retrieved ceramic components. The implantation period was positively correlated with both damage scores of the femoral heads (R = 0.573, p < 0.001) and the acetabular cups (R = 0.592, p < 0.001). Increased maximal out-of-roundness values of the femoral heads correlated with both increased metal transfer damage score (R = 0.384, p = 0.023) and increased stripe damage score (R = 0.729, p ≤ 0.001) of the acetabular liners. The damage rate (damage score/year) for both the retrieved heads and acetabular liners was at least 2.2-fold greater at inclination angles of >45° than the damage rate at inclination angles of ≤45°. For the retrieved femoral heads only, the linear wear rate of 25.5 ± 21.3 µm/year at inclination angles of >45° was 6-fold greater than the linear wear rate of 4.2 ± 2.3 µm/year at inclination angles of ≤45°. Metal transfer on the ceramic bearing surface could possibly contribute to fluid-film starvation and, in combination with an increased inclination angle, may facilitate an adhesive wear mechanism associated with stripe surface damage. At our institution, the clinical survivorship of ceramic-on-ceramic total hip replacements was 98.9% (a total of 9 out of 815 patients were revised within 10 years after total hip arthroplasty) with revision as the end point, suggesting their safe use in younger patients.

Retrieval analysis of modular total knee replacements: factors influencing backside surface damage.

Retrieved knee implants were examined to investigate the influence of patient and implant related factors on backside damage. Fifty-two implants of three different models were examined that all had cemented tibial trays without screw holes. A semi-quantitative grading system supplied backside damage scores (BDS) for each polyethylene (PE) tibial insert. Evidence was obtained to support the use of a constraining partial-peripheral locking mechanism and polished tibial tray surface (particularly for male patients) to reduce backside damage. Overall, male patients in the present study were associated with higher body mass and higher BDS compared with female patients. Furthermore, PE inserts sterilized by gamma-in-air had higher BDS than PE inserts sterilized in inert environments (gas-plasma or ethylene-oxide). Also, the proximal surfaces of tibial trays that had been grit-blasted showed embedded particles that may have increased backside damage. While none of these overall findings was unexpected, the present study provided detailed supporting analysis based on data from clinical retrievals, which may further support the use of a polished tibial tray combined with partial-peripheral locking mechanism to reduce BDS.