Micromotions at the taper interface between stem and neck adapter of a bimodular hip prosthesis during activities of daily living

Influence of the use of an adhesive connection on the joint strength of modular hip endoprostheses

INTRODUCTION

Modular hip implants enables a more precise adaptation of the prosthesis to the patient's anatomy. However, they also carry the risk of increased revision rates due to micromotion at the taper junction. In order to minimize this risk, one potential solution is to establish an adhesive bond between the metal taper junctions. Load-stable bonding techniques, already successfully employed in dentistry for connecting materials such as metals and ceramics or different alloys, offer a promising approach. Nevertheless, the bond strength of tapered adhesive bonds in modular hip implants has not been investigated to date.

MATERIALS AND METHODS

Twenty-eight tapered junctions, consisting of a taper (female taper) and a trunnion (male taper) were turned using TiAl6V4 ELI (n = 16) and CoCr28Mo6 (n = 12). The process parameters cutting speed (vc = 50 m/min or 100 m/min) and feed (f = 0.1 mm, 0.05 mm or 0.2 mm) were varied for the trunnions. For each set of process parameters, one trunnion and one taper were additionally subjected to sandblasting. To investigate the effect of geometry, angular mismatch in the samples were measured. The taper pairs were bonded with a biocompatible adhesive, and push-out tests were subsequently performed.

RESULTS

The push-out forces generated from the taper connections where both tapers were sandblasted showed a mean push-out force of 5.70 kN. For the samples with only the trunnion sandblasted, the mean force was 0.58 kN, while for the samples with only taper sandblasted the mean push-out force was 1.32 kN. When neither of the tapers was sandblasted the mean push-out force was 0.91 kN. No significant effect of the process parameters on the push-out force was observed. Only the reduced valley depth Svk showed a slight correlation for the CoCr28Mo6 samples (R2 = 0.54). The taper pairs with taper mismatch (between trunnion and taper) greater than |0.1°| did not show lower push-out forces than the specimens with lower taper mismatch.

CONCLUSIONS

Sandblasted and adhesive-bonded tapered connections represent a viable suitable alternative for modular hip implant connections. Slight differences in taper geometry do not result in reduced push-out forces and are compensated by the adhesive. In mechanically joined tapers these differences can lead to higher wear rates. Further investigation under realistic test conditions is necessary to assess long-term suitability.

Protein-metal interactions due to fretting corrosion at the taper junction of hip implants: An in vitro investigation using Raman spectroscopy

Modular hip implants are a clinically successful and widely used treatment for patients with arthritis. Despite ongoing retrieval studies the understanding of the fundamental physico-chemical mechanisms of friction and wear within the head-taper interface is still limited. Here, we Raman-spectroscopically analyze structural features of the biotribological material which is formed within the taper joint between Ti6Al4V and low-carbon cobalt alloy or high-nitrogen steel surfaces in in vitro gross-slip fretting corrosion tests with bovine calf serum. As a function of the fretting duration, we investigate short and long aliphatic chains and their adsorption behavior on the cobalt- and steel-type surfaces. Using the intensity and frequency shifts of the amide I and III Raman bands, we furthermore identify progressive protein folding and unfolding including the secondary structures of α-helix, β-sheet, and random-coil configuration as well as the formation of proteinaceous clusters depending on the hydrophilicity of the metallic surfaces. We additionally find a mixture of chromates and iron oxides with tryptophan and tyrosine at the worn cobalt alloy and high-nitrogen steel surfaces, respectively. Also, for long fretting duration, sp2 hybridized amorphous carbon is formed due to fretting-induced cleavage of proteins. STATEMENT OF SIGNIFICANCE: Despite efforts enhancing the biomedical tribology of hip implants, the impact of the organic environment on friction and wear at the femoral head-stem taper interface is limitedly understood. Using Raman spectroscopy we resolve structural changes within the biotribological material agglomerated at biomedical-grade metal alloys due to metal-organic interactions during in vitro fretting corrosion tests. Adsorption of short and long aliphatic chains, progressive protein (un)folding and proteinaceous cluster formation depend to a distinguishable extent on the fretting duration and type of alloy. Chromates and iron oxides are mixed with tryptophan and tyrosine, and amorphous carbon is formed resulting from a fretting-induced cleavage of serum proteins. Such information spectroscopically gleaned from biotribological material are vital to improve the design and performance of taper junctions.

Evolution of chromium and cobalt serum levels after the use of a modular neck stem in primary total hip arthroplasty

INTRODUCTION AND OBJECTIVES

Modular neck primary stems were introduced with the theoretical advantage of restoring the hip anatomy more precisely. However, the presence of a second junction has been associated with increased corrosion and release of metal debris. The objective of our study is to quantify of chromium and cobalt serum values, and to analyze their temporal evolution during five years.

MATERIAL AND METHODS

We present a prospective series of 61 patients who underwent primary total hip arthroplasty by implantation of the HMAX-M® stem (Limacorporate, San Daniele, Italy). Serum chromium and cobalt determinations were performed at six months, two years and five years.

RESULTS

Our series shows a progressive elevation in chromium levels with a significant difference between chromium values at six months (0.35±0.18) and five years (0.52±0.36), P=.01. Regarding cobalt, a statistically significant elevation is observed between six months and two years and a subsequent stabilization of values between two and five years, with a cobalt mean at six months (1.17±0.8) significantly lower than at two (2.63±1.76) and five years (2.84±2.1), P=.001.

CONCLUSION

Elevated serum cobalt levels have been observed in patients who underwent modular neck stem implantation. The results obtained in this study have limited the use of stems with a modular neck in our clinical practice.

[Translated article] Evolution of chromium and cobalt serum levels after the use of a modular neck stem in primary total hip arthroplasty

INTRODUCTION AND OBJECTIVES

Modular neck primary stems were introduced with the theoretical advantage of restoring the hip anatomy more precisely. However, the presence of a second junction has been associated with increased corrosion and release of metal debris. The objective of our study is to quantify of chromium and cobalt serum values, and to analyse their temporal evolution during five years.

MATERIAL AND METHODS

We present a prospective series of 61 patients who underwent primary total hip arthroplasty by implantation of the H MAX-M® stem (Limacorporate, San Daniele, Italy). Serum chromium and cobalt determinations were performed at six months, two years and five years.

RESULTS

Our series shows a progressive elevation in chromium levels with a significant difference between chromium values at six months (0.35±0.18) and five years (0.52±0.36), p=.01. Regarding cobalt, a statistically significant elevation is observed between six months and two years and a subsequent stabilisation of values between two and five years, with a cobalt mean at six months (1.17±0.8) significantly lower than at two (2.63±1.76) and five years (2.84±2.1), p=.001.

CONCLUSION

Elevated serum cobalt levels have been observed in patients who underwent modular neck stem implantation. The results obtained in this study have limited the use of stems with a modular neck in our clinical practice.

Bimodular femoral stems in primary total hip arthroplasty

INTRODUCTION

This review critically examines the efficacy of dual-modular stems in primary total hip arthroplasty. Given the variability and non-comparability of certain femoral stem designs and stem-neck couplings, with some even being withdrawn from the market, this review offers an in-depth analysis of predominant implant performances.

AREAS COVERED

The paper explores a brief historical summary related to dual-modular stems, including the complications associated with their use, diagnostic tools for evaluation, analysis of both recalled and currently available models, as well as alternative therapeutic options. This information is pertinent for both clinical and research domains.

EXPERT OPINION

While dual-modular systems were initially touted to offer several advantages, the evidence substantiating these benefits has been ambiguous. Further, these systems introduce the risk of alternative complications. In specific cases involving patients with developmental hip dysplasia and certain proximal femoral deformities requiring complex reconstructions, dual-modular systems might be relevant. Nonetheless, the use of long interchangeable necks in patients with a body mass index above 30 kg/m2 is discouraged, and pairing a long varus-oriented neck with an extra-long femoral head should be avoided in all patients.

Design and Performance Evaluation of a Novel Spiral Head-Stem Trunnion for Hip Implants Using Finite Element Analysis

With an expectation of an increased number of revision surgeries and patients receiving orthopedic implants in the coming years, the focus of joint replacement research needs to be on improving the mechanical properties of implants. Head-stem trunnion fixation provides superior load support and implant stability. Fretting wear is formed at the trunnion because of the dynamic load activities of patients, and this eventually causes the total hip implant system to fail. To optimize the design, multiple experiments with various trunnion geometries have been performed by researchers to examine the wear rate and associated mechanical performance characteristics of the existing head-stem trunnion. The objective of this work is to quantify and evaluate the performance parameters of smooth and novel spiral head-stem trunnion types under dynamic loading situations. This study proposes a finite element method for estimating head-stem trunnion performance characteristics, namely contact pressure and sliding distance, for both trunnion types under walking and jogging dynamic loading conditions. The wear rate for both trunnion types was computed using the Archard wear model for a standard number of gait cycles. The experimental results indicated that the spiral trunnion with a uniform contact pressure distribution achieved more fixation than the smooth trunnion. However, the average contact pressure distribution was nearly the same for both trunnion types. The maximum and average sliding distances were both shorter for the spiral trunnion; hence, the summed sliding distance was approximately 10% shorter for spiral trunnions than that of the smooth trunnion over a complete gait cycle. Owing to a lower sliding ability, hip implants with spiral trunnions achieved more stability than those with smooth trunnions. The anticipated wear rate for spiral trunnions was 0.039 mm³, which was approximately 10% lower than the smooth trunnion wear rate of 0.048 mm³ per million loading cycles. The spiral trunnion achieved superior fixation stability with a shorter sliding distance and a lower wear rate than the smooth trunnion; therefore, the spiral trunnion can be recommended for future hip implant systems.

Parametric analysis of the effect of impaction load on the stability of head-neck junction in total hip arthroplasty

BACKGROUND

Tribocorrosion at head-neck interface is one of the main causes leading to the failure of hip implants in total hip arthroplasty. Impaction load has been acknowledged as one of the key factors influencing the stability of the taper junction. It is understood that the magnitude of impaction force differs from the surgeon to surgeon in primary total hip arthroplasty or revision. Clinically, it is sufficient enough to keep the male and female tapers inseparable utilizing a low impaction, which seems to contradict previous researches. The objective of this study was to investigate the effect of impaction loads on the stability of taper junction during assembly and gaits.

METHODS

A finite element model with 12/14 taper and the taper mismatch of 4' was developed for investigation. The impaction force profiles were collected from surgeon as the inputs, and then the contact mechanics over one or multiple gaits was further analyzed and validated utilizing hip simulator test.

FINDINGS

Impaction force ranging from 200 to 2000 N could provide the same taper connection effect after the first gait due to the secondary seating. As for impaction loads of 3000 N and above, an increased impaction force would lead to the tighter taper connection.

INTERPRETATION

The effect of impaction load on the stability of head-neck junction is a piecewise function, indicating that the stability of taper junction is not affected by different impaction loads and tends to be consistent while its magnitude is below the threshold. Instead, the stability of taper junction is positively correlated with impaction force.

Taper corrosion: a complication of total hip arthroplasty

The focus on taper corrosion in modular hip arthroplasty increased around 2007 as a result of clinical problems with large-head metal-on-metal (MoM) bearings on standard stems. Corrosion problems with bi-modular primary hip stems focused attention on this issue even more.

Factors increasing the risk of taper corrosion were identified in laboratory and retrieval studies: stiffness of the stem neck, taper diameter and design, head diameter, offset, assembly force, head and stem material and loading.

The high variability of the occurrence of corrosion in the clinical application highlights its multi-factorial nature, identifying the implantation procedure and patient-related factors as important additional factors for taper corrosion.

Discontinuing the use of MoM has reduced the revisions due to metal-related pathologies dramatically from 49.7% (MoM > 32 mm), over 9.2% (MoM ⩽ 32 mm) to 0.8% (excluding all MoM).

Further reduction can be achieved by omitting less stiff Ti-alloys and large metal heads (36 mm and above) against polyethylene (PE).

Standardized taper assembly of smaller and ceramic heads will reduce the clinical occurrence of taper corrosion even further. If 36 mm heads are clinically indicated, only ceramic heads should be used.

Taper-related problems will not comprise a major clinical problem anymore if the mentioned factors are respected.

Cite this article: EFORT Open Rev 2020;5:776-784. DOI: 10.1302/2058-5241.5.200013

Design, Modeling, and Evaluation of the Eddy Current Sensor Deeply Implanted in the Human Body

Joint replacement surgeries have enabled motion for millions of people suffering from arthritis or grave injuries. However, over 10% of these surgeries are revision surgeries. We have first analyzed the data from the worldwide orthopedic registers and concluded that the micromotion of orthopedic implants is the major reason for revisions. Then, we propose the use of inductive eddy current sensors for in vivo micromotion detection of the order of tens of μ m. To design and evaluate its characteristics, we have developed efficient strategies for the accurate numerical simulation of eddy current sensors implanted in the human body. We present the response of the eddy current sensor as a function of its frequency and position based on the robust curve fit analysis. Sensitivity and Sensitivity Range parameters are defined for the present context and are evaluated. The proposed sensors are fabricated and tested in the bovine leg.

Effects of seating load magnitude and load orientation on seating mechanics in 5°40' mixed-alloy modular taper junctions

BACKGROUND

Mechanically-assisted crevice corrosion of modular tapers continues to be a concern in total joint replacements. Surgical factors that may affect taper seating mechanics include seating load magnitude and load orientation. Seating mechanics is defined as the seating load versus displacement behavior. In this study, mixed-alloy (CoCrMo/Ti-6Al-4V) modular head-neck 5°40' taper junctions were seated over a range of axially-oriented loads and off-axis orientations, capturing load-displacement during seating. The goals of the study were to assess the effects of seating load magnitude and load orientation on seating mechanics and correlate those findings with the taper pull-off load.

METHODS

A testing fixture measured head-neck seating displacement as the load was quasistatically applied. Motion was captured using two non-contact differential variable reluctance transducers which were mounted to the neck targeting the head. Seating experiments ranged from 1000 N to 8000 N. Load orientation ranged from 0° to 20° at 4000 N.

RESULTS

Seating load-displacement behavior at different seating loads showed a consistent characteristic behavior. Testing demonstrated increased seating displacement with seating load. Pull-off loads increased with seating load and were approximately 44% of the seating load across the range of seating loads investigated. Seating load orientation up to 20° had no significant effect on seating displacement and taper pull-off load.

CONCLUSION

Increased seating load magnitude increased seating displacement, work of seating and pull-off loads in mixed-alloy 5°40' head-neck tapers. Altering load orientation up to 20° off-axis had no significant effect. Direct measurements of seating mechanics provides insights into the locking of taper junctions.

Head Taper Corrosion Causing Head Bottoming Out and Consecutive Gross Stem Taper Failure in Total Hip Arthroplasty

BACKGROUND

Taper corrosion in total hip arthroplasty for bearings with metal heads against polyethylene has developed from an anecdotal observation to a clinical problem. Increased taper wear and even gross taper failure have been reported for one particular design. It is hypothesized that corrosion of the female head taper results in taper widening, allowing the cobalt-chromium head to turn on the stem and wear down the softer titanium alloy by abrasive wear, ultimately causing failure. The purpose of this study is to investigate the time course of this process and the general role of taper dimensions and material in this problem.

METHODS

Retrieved cobalt-chromium alloy heads (n = 30, LFIT; Stryker, Mahwah, NJ) and Ti-12Mo-6Zr-2Fe (TMZF) stems (n = 10, Accolade I; Stryker) were available for analysis. Taper material loss was determined using three-dimensional coordinate measurements and scanning. The pristine tip clearance between head and stem was analytically determined. The influence of taper material and taper size on taper deformation and micromotion was investigated using a finite element model.

RESULTS

Material loss at the head taper increased with time in situ up to a volume of 20.8 mm³ (P < .001). A mean linear material loss above 76 μm at the head taper was analytically confirmed to result in bottoming out, which was observed in 12 heads. The finite element calculations showed significantly larger deformations and micromotions for a small 11/13 TMZF taper combined with a distinctly different micromotion pattern compared to other materials and taper designs.

CONCLUSION

A 11/13 TMZF taper design with 36-mm head diameters bears a higher risk for corrosion than larger tapers made from stiffer materials. Failures of this combination are not restricted to the head sizes included in the recall. Patients with this implant combination should be closely monitored.

The Influence of Contamination and Cleaning on the Strength of Modular Head Taper Fixation in Total Hip Arthroplasty

BACKGROUND

Intraoperative interface contamination of modular head-stem taper junctions of hip implants can lead to poor fixation strength, causing fretting and crevice corrosion or even stem taper fracture. Careful cleaning before assembly should help to reduce these problems. The purpose of this study was to determine the effect of cleaning (with and without drying) contaminated taper interfaces on the taper fixation strength.

METHODS

Metal or ceramic heads were impacted onto titanium alloy stem tapers with cleaned or contaminated (fat or saline solution) interfaces. The same procedure was performed after cleaning and drying the contaminated interfaces. Pull-off force was used to determine the influence of contamination and cleaning on the taper strength.

RESULTS

Pull-off forces after contamination with fat were significantly lower than those for uncontaminated interfaces for both head materials. Pull-off forces after application of saline solution were not significantly different from those for uncontaminated tapers. However, a large variation in taper strength was observed, pull-off forces for cleaned and dried tapers were similar to those for uncontaminated tapers for both head materials.

CONCLUSION

Intraoperative contamination of taper interfaces may be difficult to detect but has a major influence on taper fixation strength. Cleaning of the stem taper with saline solution and drying with gauze directly before assembly allows the taper strength of the pristine components to be achieved. Not drying the taper results in a large variation in pull-off forces, emphasizing that drying is essential for sufficient and reproducible fixation strength.

Effects of hip implant modular neck material and assembly method on fatigue life and distraction force

Hip implant neck fractures and adverse tissue reactions associated with fretting-corrosion damage at modular interfaces are a major source of concern. Therefore, there is an urgent clinical need to develop accurate in vitro test procedures to better understand, predict and prevent in vivo implant failures. This study aimed to simulate in vivo fatigue fracture and distraction of modular necks in an in vitro setting, and to assess the effects of neck material (Ti6Al4V vs. CoCrMo) and assembly method (hand vs. impact) on the fatigue life and distraction of the necks. Fatigue tests were performed on the cementless PROFEMUR® Total Hip Modular Neck System under two different loads and number of cycles: 2.3 kN for 5 million cycles, and 7.0 kN for 1.3 million cycles. The developed in vitro simulation setup successfully reproduced in vivo modular neck fracture mode and location. Neck failure occurred at the neck-stem taper and the fracture ran from the distal lateral neck surface to the proximal medial entry point of the neck into the stem. None of the necks failed under the 2.3 kN load. However, all hand-assembled Ti6Al4V necks failed under the 7.0 kN load. In contrast, none of the hand-assembled CoCrMo necks and impact-assembled necks (Ti6Al4V or CoCrMo) failed under this higher load. In conclusion, Ti6Al4V necks were more susceptible to fatigue failure than CoCrMo necks. In addition, impact assembly substantially improved the fatigue life of Ti6Al4V necks and also led to overall higher distraction forces for both neck materials. Overall, this study shows that the material and assembly method can affect the fatigue strength of modular necks. Finally, improper implant assembly during surgery may result in diminished modular neck survivability and increased failure rates. © 2016 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 35:2023-2030, 2017.

Influence of the compliance of a patient's body on the head taper fixation strength of modular hip implants

BACKGROUND

The strength of the modular fixation between head and stem taper of total hip replacement implants should be sufficient to minimise relative motion and prevent corrosion at the interface. Intraoperatively the components are assembled by impaction with a hammer. It is unclear whether the effective compliance of the patient's body modifies the strength of the taper interface under impaction assembly. The purpose of this study was to assess the influence of the compliance of the patient's body on the taper fixation strength.

METHODS

Cobalt-chrome and ceramic femoral heads were assembled with titanium alloy stem tapers in the laboratory under impaction. Impaction forces were applied with a constant energy, defined by the drop height of the impactor, according to standard experimental procedure. The compliance of the patient was simulated in the laboratory by varying the stiffness of springs mounted below the stem taper. Pull-off forces between head and neck were measured to determine fixation strength.

FINDINGS

Decreasing spring stiffness had no effect on the applied peak impaction forces during assembly or on the pull-off forces. Pull-off forces showed no difference between metal and ceramic head materials.

INTERPRETATION

Pull-off forces and impaction forces were independent of the spring stiffness below the stem taper, indicating that the compliance of the patient has no effect on the taper fixation strength. Impaction testing in the laboratory can therefore be performed under rigid fixation, without accounting for the compliance of the patient.

The taper corrosion pattern observed for one bi-modular stem design is related to geometry-determined taper mechanics

Bi-modular primary hip stems exhibit high revision rates owing to corrosion at the stem-neck taper, and are associated with local adverse tissue reactions. The aim of this study was to relate the wear patterns observed for one bi-modular design to its design-specific stem-neck taper geometry. Wear patterns and initial geometry of the taper junctions were determined for 27 retrieved bi-modular primary hip arthroplasty stems (Rejuvenate, Stryker Orthopaedics) using a tactile coordinate-measuring device. Regions of high-gradient wear patterns were additionally analyzed via optical and electron microscopy. The determined geometry of the taper junction revealed design-related engagement at its opening (angle mismatch), concentrated at the medial and lateral apexes (axes mismatch). A patch of retained topography on the proximal medial neck-piece taper apex was observed, surrounded by regions of high wear. On the patch, a deposit from the opposing female stem taper-containing Ti, Mo, Zr, and O-was observed. High stress concentrations were focused at the taper apexes owing to the specific geometry. A medial canting of the components may have augmented the inhomogeneous stress distributions in vivo. In the regions with high normal loads interfacial slip and consequently fretting was inhibited, which explains the observed pattern of wear.

Will New Metal Heads Restore Mechanical Integrity of Corroded Trunnions?

BACKGROUND

Metal wear and corrosion from modular junctions in total hip arthroplasty can lead to further unwanted surgery. Trunnion tribocorrosion is recognized as an important contributor to failure. This study was performed to determine if new metal heads restore mechanical integrity of the original modular junction after impaction on corroded trunnions, and assess which variables affect stability of the new interface created at revision total hip arthroplasty.

METHODS

Twenty-two trunnions, cobalt-chromium (CoCr) and titanium alloy (TiAIV), (CoCr, n = 12; TiAIV, n = 10) and new metal heads were used, 10 trunnions in pristine condition and 12 with corrosion damage. Test states were performed using an MTS Machine and included the following: 1, Assembly; 2, Disassembly; 3, Assembly; 4, Toggling; and 5, Disassembly. During loading, three-dimensional motion of the head-trunnion junction was measured using a custom jig.

RESULTS

There were no statistical differences in the tested mechanical properties between corroded and pristine trunnions implanted with a new metal femoral head. Average micromotion of the head versus trunnion interface was greatest at the start of loading, stabilizing after approximately 50 loading cycles at an average of 30.6 ± 3.2 μm.

CONCLUSION

Corrosion at the trunnion does not disrupt mechanical integrity of the junction when a CoCr head is replaced with a CoCr trunnion. However, increased interface motion of a new metal head on a corroded titanium trunnion requires additional study. The evaluation of ball head size on mechanical integrity of trunnions would also be a potential subject of future investigation, as increasing the ball head size at the time of revision is not uncommon in revisions today.

Corrosion of the Head-Stem Taper Junction-Are We on the Verge of an Epidemic?: Review Article

BACKGROUND

The modular head taper junction has contributed to the success of total hip arthroplasty (THA) greatly. Taper corrosion and wear problems reported for large and extra-large metal-on-metal bearings as well as for bi-modular THA stems have cast doubt on the benefit of the taper interface. Presently, corrosion problems are being reported for nearly all kinds of artificial hip joints incorporating metal heads, questioning taper connections in general.

QUESTIONS/PURPOSES

This study aimed to review the mechanical and electrochemical relationships that may lead to taper corrosion, which have been reported more commonly in recent literature, and to also review the contribution of patient characteristics and surgical techniques involved in taper assembly that may contribute to the problem.

METHODS

The search criteria "(corrosion) AND (hip arthroplasty) AND (taper OR trunnion)" and "(hip arthroplasty) AND ((pseudotumor) OR (pseudo-tumor))" in PubMed and the JAAOS were used for the literature search. In addition, the arthroplasty registers were considered.

RESULTS

Most studies acknowledge the multifactorial nature of the problem but concentrate their analysis on taper and implant design aspects, since this is the only factor that can be easily quantified. The sometimes conflicting results in the literature could be due to the fact that the other two decisive factors are not sufficiently considered: the loading situation in the patient and the assembly situation by the surgeon. All three factors together determine the fate of a taper junction in THA. There is no single reason as a main cause for taper corrosion. The combined "outcome" of these three factors has to be in a "safe range" to achieve a successful long-term taper fixation.

CONCLUSION

No, this is not the beginning of an epidemic. It is rather the consequence of disregarding known mechanical and electrochemical relationships, which in combination have recently caused a more frequent occurrence-and mainly reporting-of corrosion issues.

Effect of trunnion roughness and length on the modular taper junction strength under typical intraoperative assembly forces

Modular hip implants are at risk of fretting-induced postoperative complications most likely initiated by micromotion between adjacent implant components. A stable fixation between ball head and stem-neck taper is critical to avoid excessive interface motions. Therefore, the aim of this study was to identify the effect of trunnion roughness and length on the modular taper strength under typical intraoperative assembly forces. Custom-made Titanium trunnions (standard/mini taper, smooth/grooved surface finish) were assembled with modular Cobalt-chromium heads by impaction with peak forces ranging from 2kN to 6kN. After each assembly process these were disassembled with a materials testing machine to detect the pull-off force as a measure for the taper strength. As expected, the pull-off forces increased with rising peak assembly force (p < 0.001). For low and moderate assembly forces, smooth standard tapers offered higher pull-off forces compared to grooved tapers (p < 0.038). In the case of an assembly force of 2kN, mini tapers showed a higher taper strength than standard ones (p=0.037). The results of this study showed that smooth tapers provided a higher strength for taper junctions. This higher taper strength may reduce the risk of fretting-related complications especially in the most common range of intraoperative assembly forces.

Particle Disease: A Current Review of the Biological Mechanisms in Periprosthetic Osteolysis After Hip Arthroplasty

Background:

Inflammatory responses to wear debris cause osteolysis that leads to aseptic prosthesis loosening and hip arthroplasty failure. Although osteolysis is usually associated with aseptic loosening, it is rarely seen around stable implants. Aseptic implant loosening is a simple radiologic phenomenon, but a complex immunological process. Particulate debris produced by implants most commonly causes osteolysis, and this is called particle-associated periprosthetic osteolysis (PPO).

Objective:

The objective of this review is to outline the features of particle-associated periprosthetic osteolysis to allow the physician to recognise this condition and commence early treatment, thereby optimizing patient outcome.

Methods:

A thorough literature search was performed using available databases, including Pubmed, to cover important research published covering particle-associated PPO.

Results:

Although osteolysis causes bone resorption, clinical, animal, and in vitro studies of particle bioreactivity suggest that particle-associated PPO represents the culmination of several biological reactions of many cell types, rather than being caused solely by the osteoclasts. The biological activity is highly dependent on the characteristics and quantity of the wear particles.

Conclusion:

Despite advances in total hip arthroplasty (THA), particle-associated PPO and aseptic loosening continue to be major factors that affect prosthetic joint longevity. Biomarkers could be exploited as easy and objective diagnostic and prognostic targets that would enable testing for osteolysis after THA. Further research is needed to identify new biomarkers in PPO. A comprehensive understanding of the underlying biological mechanisms is crucial for developing new therapeutic interventions to reverse or suppress biological responses to wear particles.

The taper disaster--how could it happen?

Corrosion of metallic implants in contact with body fluids is unavoidable, especially at interfaces where movement occurs or in gaps. Corrosion became clinically relevant with the introduction of large modular metal-on-metal total hip joint articulations (MoM THA) early in the 21st century. This review attempts to summarise the scientific knowledge about taper problems available at the time of introduction of these bearings, why this "disaster" could happen. It is speculated that changes to the taper connection made in the 1990s to increase the range of motion with small heads (28 and 32 mm) reduced the mechanical strength of this connection, which did not matter for small heads. With the use of large and very large metal heads in MoM articulations, which have a larger lever arm and can generate high friction in unfavourable situations, suddenly the taper interface exhibited corrosion problems on a previously unknown scale. It is speculated that due to the higher mechanical loading with larger heads, the taper connection became less forgiving with respect to assembly conditions, contamination, manufacturing tolerances and other factors, which are yet not known. Since no major clinical problems had been reported before the introduction of these bearings and the pre-clinical testing was very successful, the disaster took its course. The patient-implant-surgeon system is a very complex intrinsically hazardous system. Pre-clinical testing addresses few and defined factors and such, good results cannot be directly transferred to the clinical reality. A controlled stepwise introduction of innovations is required.

Assembly force and taper angle difference influence the relative motion at the stem–neck interface of bi-modular hip prostheses

Bi-modular hip arthroplasty prostheses allow adaptation to the individual patient anatomy and the combination of different materials but introduce an additional interface, which was related lately to current clinical issues. Relative motion at the additional taper interface might increase the overall risk of fretting, corrosion, metallic debris and early failure. The aim of this study was to investigate whether the assembly force influences the relative motion and seating behaviour at the stem–neck interface of a bi-modular hip prosthesis (Metha®; Aesculap AG, Tuttlingen, Germany) and whether this relation is influenced by the taper angle difference between male and female taper angles. Neck adapters made of titanium (Ti6Al4V) and CoCr (CoCr29Mo) were assembled with a titanium stem using varying assembly forces and mechanically loaded. A contactless eddy current measurement system was used to record the relative motion between prosthesis stem and neck adapter. Higher relative motion was observed for Ti neck adapters compared to the CoCr ones (p < 0.001). Higher assembly forces caused increased seating distances (p < 0.001) and led to significantly reduced relative motion (p = 0.019). Independent of neck material type, prostheses with larger taper angle difference between male and female taper angles exhibited decreased relative motion (p < 0.001). Surgeons should carefully use assembly forces above 4 kN to decrease the amount of relative motion within the taper interface. Maximum assembly forces, however, should be limited to prevent periprosthetic fractures. Manufacturers should optimize taper angle differences to increase the resistance against relative motion.

High Risk of Failure With Bimodular Femoral Components in THA

BACKGROUND

The bimodular femoral neck implant (modularity in the neck section and prosthetic head) offers several implant advantages to the surgeon performing THAs, however, there have been reports of failure of bimodular femoral implants involving neck fractures or adverse tissue reaction to metal debris. We aimed to assess the results of the bimodular implants used in the THAs we performed.

QUESTIONS/PURPOSES

We asked: (1) What is the survivorship of the PROFEMUR(®) bimodular femoral neck stems? (2) What are the modes of failure of this bimodular femoral neck implant? (3) What are the major risk factors for the major modes of failure of this device?

METHODS

Between 2003 and 2009, we used one family of bimodular femoral neck stems for all primary THAs (PROFEMUR(®) Z and PROFEMUR(®) E). During this period, 277 THAs (in 242 patients) were performed with these implants. One hundred seventy were done with the bimodular PROFEMUR(®) E (all are accounted for here), and when that implant was suspected of having a high risk of failure, the bimodular PROFEMUR(®) Z was used instead. One hundred seven THAs were performed using this implant (all are accounted for in this study). All bearing combinations, including metal-on-metal, metal-on-polyethylene, and ceramic-on-ceramic, are included here. Data for the cohort included patient demographics, BMI, implant dimensions, type of articular surface, length of followup, and C-reactive protein serum level. We assessed survivorship of the two stems using Kaplan-Meier curves and determined the frequency of the different modes of stem failure. For each of the major modes of failure, we performed binary logistic regression to identify associated risk factors.

RESULTS

Survivorship of the stems, using aseptic revision as the endpoint, was 85% for the patients with the PROFEMUR(®) E stems with a mean followup of 50 months (range, 1-125 months) and 85% for the PROFEMUR(®) Z with a mean followup of 50 months (range, 1-125 months)(95% CI, 74-87 months). The most common modes of failure were loosening (9% for the PROFEMUR(®) E), neck fracture (6% for the PROFEMUR(®) Z and 0.6% for the PROFEMUR(®) E), metallosis (1%), and periprosthetic fracture (1%). Only the bimodular PROFEMUR(®) E was associated with femoral stem loosening (odds ratio [OR] =1.1; 95% CI, 1.04-1.140; p = 0.032). Larger head (OR = 3.2; 95% CI, 0.7-14; p = 0.096), BMI (OR = 1.19; 95% CI, 1-1.4; p = 0.038) and total offset (OR = 1.83; 95% CI, 1.13-2.9; p = 0.039) were associated with neck fracture.

CONCLUSION

Bimodular neck junctions may be potentiated by long neck lengths, greater offset, and larger head diameters. These factors may contribute to bimodular neck failure by creating a larger moment about the neck's insertion in the stem. The PROFEMUR(®) E implant is associated with high periprosthetic loosening. Based on our experience we cannot recommend the use of bimodular femoral neck implants.

LEVEL OF EVIDENCE

Level III, therapeutic study.

Serum Metal Ions with a Titanium Modular Neck Total Hip Replacement System

The goal of this study is to evaluate serum levels of chromium (Cr), cobalt (Co), and titanium (Ti) within the first two years following total hip arthroplasty using a Ti modular neck system. Twenty-five patients were randomized to a metal-on-metal (MoM) bearing with an all CoCr shell, and the remaining 25 received a metal-on-polyethylene (MoP) with a Ti shell. Serum levels demonstrated increases for Cr, Co, and Ti at 1 year (P < .001). MoM had similar Ti levels to MoP hips at 1 year (P=0.11) but lower at 2 years (P=0.03). Results suggest that the passive corrosion (i.e., chemical, pitting, and crevice corrosion) of exposed non-articular metal surfaces may be a greater source of ions than the neck-stem or head-neck interfaces.

Corrosion and Fretting of a Modular Hip System: A Retrieval Analysis of 60 Rejuvenate Stems

Femoral stems with dual-taper modularity were introduced to allow independent control of length, offset, and version. Corrosion and fretting related to micromotion at the neck-stem junction are thought to stimulate an adverse local tissue reaction (ALTR). Analysis of 60 consecutively retrieved modular-neck stem implants (Rejuvenate, Stryker) revised primarily for ALTR was done to determine the variables influencing corrosion and fretting patterns at the neck-stem interface. Taper damage evaluation was performed with stereomicrocopic analysis with two observers. Evidence of fretting and corrosion was seen at the neck-stem taper in all implants, including three implants revised for periprosthetic fractures within four weeks of the index surgery indicating that this process starts early. Femoral stems paired with the long overall neck lengths had significantly higher corrosion scores. Correlation of the corrosion severity at particular locations with the length of implantation suggests that the neck-stem junction experiences cyclic cantilever bending in vivo. The positive correlation between the length of implantation and fretting/corrosion scores bodes poorly for patients who still have this implant. Scanning electron microscopy on a subset of specimens was also performed to evaluate the black corrosion material. We strongly urge frequent follow-up exams for every patient with this particular modular hip stem.

Trunnion-Head Stresses in THA: Are Big Heads Trouble?

The effects of large heads on stresses at the THA trunnion-head junction and their impact on tribocorrosion/metal ion release remain controversial. A 12/14 3D-model of a stem with different head sizes was investigated. Material properties of titanium were assigned to the trunnion and cobalt-chrome/alumina to the heads. A load simulating walking single-leg stand phase was applied to the head. A total contact head-trunnion interface was assumed. The area underneath the junction underwent significant elevations in stresses as head size increased from 28- to 40-mm. Maximum principal stress doubled between 28 and 40-mm heads, regardless of head material. Stress levels had a direct correlation to head diameter. Stress increases observed using increasingly larger heads will probably contribute to head-trunnion tribocorrosion and ion release.

Are asymmetric metal markings on the cone surface of ceramic femoral heads an indication of entrapped debris?

BACKGROUND

The probability of in vivo failure of ceramic hip joint implants is very low (0.004-0.05%). In addition to material flaws and overloading, improper handling during implantation can induce fractures of the ceramic ball head in the long term. Identifying the causes of an in vivo fracture contributes to improved understanding and potentially to further reduction of the fracture probability for patients. Asymmetric metal markings on the cone surface of in vivo ball head fractures have been reported. The question, therefore, is whether asymmetric loading is the sole cause or whether additional factors, specifically contamination entrapped in the taper fit, also contribute or are even the main cause.

METHODS

The influence of the asymmetric physiological load configuration on resulting metal markings in the cone surface of an alumina femoral ball head with and without biological contaminants was investigated. Static and cyclic tests on ball heads were carried out in a load configuration of 0° (axisymmetric) and 40° in a physiological environment. The analysis of the metal marking was carried out to gain a better understanding of the processes that contribute to the generation of metal marking. Fractography was carried out to determine the fracture initiation of failed ball heads.

RESULTS

Different types and sizes of residuals entrapped in the conical surface are shown to yield strongly asymmetric metal marking patterns. All heads tested without contaminants exhibited an almost homogenous distribution of residual metal markings around the circumference of the ceramic cone surface at the proximal end of the bore hole. The failure of ball heads that contained entrapped contaminants revealed a common fracture pattern. The site of fracture initiation on two of the failed heads was in the entrance region of the bore hole on the superior half of the head.

CONCLUSION

Asymmetric metal markings observed on the ball heads tested in this investigation are most probably caused by the presence of contaminants entrapped in the taper fit. Homogenous metal mark distributions around the circumference indicate proper assembly of the ball head without entrapped contaminants. It should, however, be noted that different taper designs may possibly result in different marking patterns.