Pushing Ceramic-on-Ceramic in the most extreme wear conditions: A hip simulator study

Computed Tomography Evaluation of Alumina Ceramic-on-Ceramic Total Hip Arthroplasty With More Than 20 years of Follow-Up: Is a Follow-Up Computed Tomography Scan Necessary?

BACKGROUND

Ceramic-on-ceramic (CoC) bearings have been increasingly used in total hip arthroplasty (THA) because of their superior wear resistance and biocompatibility. However, there is a scarcity of reports on the computed tomography (CT) evaluation of CoC bearings with more than 10 years. The aim of this study was to evaluate the long-term CT results of THA using CoC bearings for more than 20 years of follow-up. We hypothesized that there would be no wear, osteolysis, or ceramic fracture.

METHODS

Between November 1997 and June 2003, 956 hips underwent THA using alumina-on-alumina bearings at a tertiary referral hospital. Among them, 107 hips were assessed, all of which underwent a CT examination more than 20 years after the index surgery. The mean age at the time of surgery was 41 years, and a CT scan was performed at an average of 22.0 years postoperatively (range, 20.0 to 25.1). The CT scans were thoroughly assessed for osteolysis, stem notching, and ceramic component fracture.

RESULTS

No loosening was observed in the acetabular cup or femoral stem. Stem notching was observed in 3 hips (2.8%). In the CT scan taken after a minimum of 20 years of follow-up, 1 case (0.9%) of osteolysis around the cup and 2 cases (1.9%) of osteolysis around the femoral stem were noted. Suspected chip fractures of the ceramic insert were discovered in 4 cases (3.7%). Despite these findings, the patients remained asymptomatic, and no subsequent surgical intervention was needed after close follow-up.

CONCLUSIONS

Routine CT examinations for patients who underwent THA using CoC bearings over 20 years ago revealed unexpected findings, such as osteolysis and suspected chip fractures of the ceramic liner. However, routine CT scans may not be universally necessary. The CT evaluation in this cohort should be selectively performed for patients who have relevant clinical symptoms.

LEVEL OF EVIDENCE

Level III, Therapeutic study.

Surface adhered titanium particles on 3D printed off-the-shelf acetabular cups

3D printing is a rapidly growing manufacturing method of medical implants. In orthopedics, this method enables the construction of complex porous structures with the aim of improved bone fixation. A known by-product of the 3D printing process is surface adhered particles which are often challenging to remove from the strut surfaces of the porous region. This study investigates the presence of these particles in the porous region of unused 3D printed off-the-shelf acetabular cup from five manufacturers. Scanning Electron Microscopy (SEM) and image analysis software were used to determine the frequency and diameters of particles present on these implants. Surface adhered particles were found in the porous structures of all implants with some exhibiting more particles at the subsurface level than the surface level. Implants manufactured via Selective Laser Melting (SLM) exhibited a higher number of surface adhered particles per mm2 at both the surface and subsurface levels than those manufactured by Electron Beam Melting (EBM). Additionally, and consistent with previous literature, the particle diameter of the SLM cups was found to be smaller than those on the EBM cups, as well as having a visually lower level of adherence which could raise concern about the likelihood of breakage of these particles in-vivo.

Proof of Concept of a New Revision Procedure for Ceramic Inlays of Acetabular Cups Using a Shape-Memory Alloy Actuator System

The revision of ceramic inlays of acetabular cups is a challenging surgical procedure. The mechanical impact during the inlay extraction process can damage the ceramic or metal cup rim. To avoid these risks, a concept for a new revision procedure was developed. It is based on an actuator system, which allows a non-destructive release of the ceramic inlay. To integrate the actuator system, different design concepts of acetabular cup components were investigated, and an actuator based on shape-memory alloy (SMA) wires was developed. The process chain for the actuator, starting from nickel-titanium wires manufactured into the actuator geometry by laser welding and thermo-mechanical treatment for the shape setting process up to the functionality evaluation of the actuator system, was implemented on a laboratory scale. The new revision procedure is based on a phase transformation of the SMA wire actuator, which was obtained through two methods-applying an electrical current by an instrument and rinsing the wire with heated water. The phase transformation of the actuator resulted in a contraction between 3.2% and 4.3% compared to its length after pre-stretching and was able to release the ceramic inlay from the cup. Therefore, the developed actuator design and process chain is a proof of concept towards a new revision procedure for modular acetabular cups.

Ceramic-related noise as an adverse outcome in total hip arthroplasty

Introduction Ceramic hip replacement bearings have shown to be low wearing and biocompatible. The last two generations of Biolox Forte and Biolox Delta ceramics have have established themselves as durable bearings. However, squeaking and noise from ceramic bearing THRs is well recognised in the 21st century.

The objective was to explore the problem of noise in the ceramic bearing of THA based on the analysis of the foreign and Russian literature.

Material and methods In presented the analysis of Foreign and Russian literature searches for the review were produced according to PRISMA recommendations using PubMed, Scopus, Google Scholar, eLibrary. MINOR was used to assess the methodological quality of articles.

Results and Discussion Noise in ceramics is observed in 37.7 %. There are many theories on the origin and mechanism of noise including liner impingement and loading, film disruption, third body, microseparation and resonance. However, there is still no consensus on what is noise in the ceramic bearing and how to solve this problem.

Conclusion Literature review of ceramic bearing indicated enough unanswered questions. The noise may play a role as a predictor of improper use of endoprosthesis with accumulated database resulting in better understanding of the phenomenon, methods of the correction and timely prevention of ceramic breakage.

Ceramic Wear Particles: Can They Be Retrieved In Vivo and Duplicated In Vitro?

BACKGROUND

Little is known about retrieved zirconia platelet toughened alumina (ZPTA) wear particles from ceramic-on-ceramic (COC) total hip arthroplasty. Our objectives were to evaluate clinically retrieved wear particles from explanted periprosthetic hip tissues and to analyze the characteristics of in vitro-generated ZPTA wear particles.

METHODS

Periprosthetic tissue and explants were received for 3 patients who underwent a total hip replacement of ZPTA COC head and liner. Wear particles were isolated and characterized via scanning electron microscopy and energy dispersive spectroscopy. The ZPTA and control (highly cross-linked polyethylene and cobalt chromium alloy) were then generated in vitro using a hip simulator and pin-on-disc testing, respectively. Particles were assessed in accordance with American Society for Testing and Materials F1877.

RESULTS

Minimal ceramic particles were identified in the retrieved tissue, consistent with the retrieved components demonstrating minimal abrasive wear with material transfer. Average particle diameter from in vitro studies was 292 nm for ZPTA, 190 nm for highly cross-linked polyethylene, and 201 nm for cobalt chromium alloy.

CONCLUSION

The minimal number of in vivo ZPTA wear particles observed is consistent with the successful tribological history of COC total hip arthroplasties. Due to the relatively few ceramic particles located in the retrieved tissue, in part due to implantation times of 3 to 6 years, a statistical comparison was unable to be made between the in vivo particles and the in vitro-generated ZPTA particles. However, the study provided further insight into the size and morphological characteristics of ZPTA particles generated from clinically relevant in vitro test setups.

Role of Interfacial Bonding in Tribochemical Wear

Tribochemical wear of contact materials is an important issue in science and engineering. Understanding the mechanisms of tribochemical wear at an atomic scale is favorable to avoid device failure, improve the durability of materials, and even achieve ultra-precision manufacturing. Hence, this article reviews some of the latest developments of tribochemical wear of typical materials at micro/nano-scale that are commonly used as solid lubricants, tribo-elements, or structural materials of the micro-electromechanical devices, focusing on their universal mechanisms based on the studies from experiments and numerical simulations. Particular focus is given to the fact that the friction-induced formation of interfacial bonding plays a critical role in the wear of frictional systems at the atomic scale.

A review of advances in tribology in 2020–2021

Around 1,000 peer-reviewed papers were selected from 3,450 articles published during 2020–2021, and reviewed as the representative advances in tribology research worldwide. The survey highlights the development in lubrication, wear and surface engineering, biotribology, high temperature tribology, and computational tribology, providing a show window of the achievements of recent fundamental and application researches in the field of tribology.

Third body damage and wear in arthroplasty bearing materials: A review of laboratory methods

Third body wear of arthroplasty bearing materials can occur when hard particles such as bone, bone cement or metal particles become trapped between the articulating surfaces. This can accelerate overall implant wear, potentially leading to early failure. With the development of novel bearing materials and coatings, there is a need to develop and standardise test methods which reflect third body damage seen on retrieved implants. Many different protocols and approaches have been developed to replicate third body wear in the laboratory but there is currently no consensus as to the optimal method for simulating this wear mode, hence the need to better understand existing methods. The aim of this study was to review published methods for experimental simulation of third body wear of arthroplasty bearing materials, to discuss the advantages and limitations of different approaches, the variables to be considered when designing a method and to highlight gaps in the current literature. The methods were divided into those which introduced abrasive particles into the articulating surfaces of the joint and those whereby third body damage is created directly to the articulating surfaces. However, it was found that there are a number of parameters, for example the influence of particle size on wear, which are not yet fully understood. The study concluded that the chosen method or combination of methods used should primarily be informed by the research question to be answered and risk analysis of the device.

Is Surface Metastability of Today’s Ceramic Bearings a Clinical Issue?

Recent studies on zirconia-toughened alumina (ZTA) evidenced that in vivo aged implants display a much higher monoclinic zirconia content than expected from in vitro simulations by autoclaving. At the moment, there is no agreement on the source of this discrepancy: Some research groups ascribe it to the effect of mechanical impact shocks, which are generally not implemented in standard in vitro aging or hip walking simulators. Others invoke the effect of metal transfer, which should trigger an autocatalytic reaction in the body fluid environment, accelerating the kinetics of tetragonal-to-monoclinic transformation in vivo. Extrapolations of the aging kinetics from high (autoclave) to in vivo temperature are also often disputed. Last, Raman spectroscopy is by far the preferred method to quantify the amount of monoclinically transformed zirconia. There are, however, many sources of errors that may negatively affect Raman results, meaning that the final interpretation might be flawed. In this work, we applied Raman spectroscopy to determine the monoclinic content in as-received and in vitro aged ZTA hip joint implants, and in one long-term retrieval study. We calculated the monoclinic content with the most used equations in the literature and compared it with the results of X-ray diffraction obtained on a similar probe depth. Our results show, contrary to many previous studies, that the long-term surface stability of ZTA ceramics is preserved. This suggests that the Raman technique does not offer consistent and unique results for the analysis of surface degradation. Moreover, we discuss here that tetragonal-to-monoclinic transformation is also necessary to limit contact damage and wear stripe extension. Thus, the surface metastability of zirconia-containing ceramics may be a non-issue.