Variation in the wear rate during the life of a total hip arthroplasty: a simulator and retrieval study

Average 22-Year Results of Total Hip Arthroplasty Using Harris-Galante Prosthesis in Patients under 50 Years

Background

The Harris-Galante (HG) prosthesis is a first-generation, cementless total hip arthroplasty (THA) prosthesis. Considering the recent increase in the demand for THA in young patients and their life expectancy, a study with a follow-up duration of longer than 20 years in a young population is needed. Therefore, we evaluated the long-term clinical and radiographic results after cementless THA using the HG prosthesis in patients younger than 50 years.

Methods

A total of 61 THAs performed using the HG with a minimum follow-up of 10 years were included. There were 38 men and 11 women with an average age of 46 years and the mean follow-up duration was 22 years. Clinical evaluation included modified Harris Hip Score (HHS) and radiographic analysis consisted of cup inclination, anteversion angle, component stability, osteolysis, liner wear rate, wear-through, liner dissociation, and heterotopic ossification. Complications included recurrent dislocation, periprosthetic femoral fracture, and periprosthetic joint infection. Survivorship analysis included cup and stem revision for aseptic loosening, as well as any revision.

Results

The HHS improved from 46.5 preoperatively to 81.8 postoperatively (p < 0.001). The average linear wear rate was 0.36 mm/yr. A total of 34 hips (56%) were revised: stem revision in 10 (16.4%), cup revision in 9 (14.8%), exchange limited to bearing surface in 8 (13.1%), and revision of all components in 7 (11.5%). Estimated survivorship at 34 years postoperatively was 90.9% for cup revision for aseptic loosening, 80.5% for stem revision for aseptic loosening, and 22.1% for any revision.

Conclusions

THA using the HG prosthesis showed satisfactory estimated survivorship of the acetabular and femoral components at 34 years postoperatively with good clinical outcomes. Bearing-related problems, such as osteolysis and liner dissociation, accounted for 56% of revision operations and were concerns in patients younger than 50 years.

Simultaneous measurement of friction and wear in hip simulators

We propose and have evaluated a method to measure hip friction during wear testing on a popular multi-station hip simulator. A 6-degree-of-freedom load cell underneath the specimen sensed forces and torques during implant wear testing of simulated walking. This included internal–external and adduction–abduction rotations which are often neglected during friction testing on pendulum-type machines. Robust mathematical analysis and data processing provided friction estimates in three simultaneous orthogonal rotations, over extended multi-million cycle wear tests. We tested various bearing couples including metal-on-plastic, ceramic-on-plastic, and metal-on-metal material couples. In one test series, new and intentionally scratched CoCrMo 40-mm-diameter femoral heads were tested against conventional ultrahigh-molecular-weight polyethylene, highly cross-linked, and highly cross-linked with vitamin E versions. The scratching significantly increased friction and doubled the wear of all groups. Before scratching, friction levels for the aforementioned plastic groups were 0.056 ± 0.0060, 0.062 ± 0.0080, and 0.070 ± 0.0045, respectively, but after scratching increased to 0.088 ± 0.018, 0.076 ± 0.0066, and 0.082 ± 0.0049, respectively, all statistically significant increases (p = 0.00059, 0.00005, 0.0115, respectively). In another test series of 44-mm femoral head diameter hips, metal-on-plastic hips with conventional ultrahigh-molecular-weight polyethylene showed the lowest friction at 0.045 ± 0.0085, followed by highly cross-linked with 0.046 ± 0.0035 (not significantly different). In a ceramic-on-plastic design with conventional ultrahigh-molecular-weight polyethylene, higher friction 0.079 ± 0.0070 was measured likely due to that ceramic surface being rougher than usual. Metal-on-metal hips were compared without and with a TiN coating, resulting in 0.049 ± 0.014 and 0.097 ± 0.020 friction factors, respectively (statistically significant, p < 0.001), and the coating wore away on all coated hips eventually. Higher friction mostly correlated with higher wear or damage to femoral heads or implant coatings, except for the highly cross-linked wear resistant ultrahigh-molecular-weight polyethylene which had slightly higher friction, confirming the same finding in other independent studies. This type of friction measurements can help screen for clamping and elevated wear of metal-on-metal and resurfacing total hip replacements, surgical malpositioning, and abraded and otherwise damaged surfaces.

Wear testing of total hip replacements under severe conditions

Controlled wear testing of total hip replacements in hip joint simulators is a well-established and powerful method, giving an extensive prediction of the long-term clinical performance. To understand the wear behavior of a bearing and its limits under in vivo conditions, testing scenarios should be designed as physiologically as possible. Currently, the ISO standard protocol 14242 is the most common preclinical testing procedure for total hip replacements, based on a simplified gait cycle for normal walking conditions. However, in recent years, wear patterns have increasingly been observed on retrievals that cannot be replicated by the current standard. The purpose of this study is to review the severe testing conditions that enable the generation of clinically relevant wear rates and phenomena. These conditions include changes in loading and activity, third-body wear, surface topography, edge wear and the role of aging of the bearing materials.

Force-controlled dynamic wear testing of total ankle replacements

Currently, our knowledge of wear performance in total ankle replacements is limited. The aim of this study is to develop a scenario for force-controlled testing and wear testing of total ankle replacements. A force-controlled wear test was developed: based on cadaver measurements, the passive stabilization (ligaments and soft tissue) of the ankle joint was characterized and a restraint model for ankle stabilization was developed. Kinematics and kinetics acting at the replaced ankle joint were defined based on literature data and gait analysis. Afterwards, force-controlled wear testing was carried out on a mobile, three-component, total ankle replacement design. Wear was assessed gravimetrically and wear particles were analyzed. Wear testing resulted in a mean wear rate of 18.2±1.4mm(3)/10(6) cycles. Wear particles showed a mean size of 0.23μm with an aspect ratio of 1.61±0.96 and a roundness of 0.62±0.14. Wear testing of total ankle replacement shows that a relevant wear mass is generated with wear particles in a biologically relevant size range. The developed wear test provides a basis for future wear testing of total ankle replacements.

Encoding scratch and scrape features for wear modeling of total joint replacements

Damage to hard bearing surfaces of total joint replacement components typically includes both thin discrete scratches and broader areas of more diffuse scraping. Traditional surface metrology parameters such as average roughness (R_a) or peak asperity height (R_p) are not well suited to quantifying those counterface damage features in a manner allowing their incorporation into models predictive of polyethylene wear. A diffused lighting technique, which had been previously developed to visualize these microscopic damage features on a global implant level, also allows damaged regions to be automatically segmented. These global-level segmentations in turn provide a basis for performing high-resolution optical profilometry (OP) areal scans, to quantify the microscopic-level damage features. Algorithms are here reported by means of which those imaged damage features can be encoded for input into finite element (FE) wear simulations. A series of retrieved clinically failed implant femoral heads analyzed in this manner exhibited a wide range of numbers and severity of damage features. Illustrative results from corresponding polyethylene wear computations are also presented.

A novel formulation for scratch-based wear modelling in total hip arthroplasty

Damage to the femoral head in total hip arthroplasty often takes the form of discrete scratches, which can lead to dramatic wear acceleration of the polyethylene (PE) liner. Here, a novel formulation is reported for finite element (FE) analysis of wear acceleration due to scratch damage. A diffused-light photography technique was used to globally locate areas of damage, providing guidance for usage of high-magnification optical profilometry to determine individual scratch morphology. This multiscale image combination allowed comprehensive input of scratch-based damage patterns to an FE Archard wear model, to determine the wear acceleration associated with specific retrieval femoral heads. The wear algorithm imposed correspondingly elevated wear factors on areas of PE incrementally overpassed by individual scratches. Physical validation was provided by agreement with experimental data for custom-ruled scratch patterns. Illustrative wear acceleration results are presented for four retrieval femoral heads.

In vivo femoral head damage and its effect on polyethylene wear

The purposes of this study were to determine the spectrum of femoral head damage in patients undergoing revision total hip arthroplasty and to determine the impact of that damage on polyethylene wear. One hundred eight consecutive modular metal femoral heads were retrieved at revision surgery. The mean roughness (Ra) value was 0.18 +/- 0.18 microm. The roughest femoral heads (mean Ra, 0.56 microm) were from retrievals correlated with mode 2 wear (recurrent dislocation and complete wear through of the polyethylene liner). Five million cycles of wear tests were performed using retrieved femoral heads against both new conventional and highly cross-linked polyethylene. The mean wear rate of conventional polyethylene was 15.9 +/- 4.3 mg and that of highly cross-linked polyethylene was 0.04 +/- 0.14 mg per 1 million cycles (P < .001). Highly cross-linked polyethylene was more resistant to wear than conventional polyethylene, even when mated against roughened femoral heads.

[Should monobloc cemented stems be systematically revised during revision total hip arthroplasty? A prospective evaluation]

PURPOSE OF THE STUDY

The main reason for revision of Charnley type total hip arthroplasty is socket loosening related to high polyethylene wear and periacetabular osteolysis. In these situations, the monobloc cemented stem is frequently not loosened and it is not clear whether the femoral component can be retained during the revision procedure. The aim of this study was to evaluate surface and sphericity damage to the femoral head of a prospective and consecutive series of revision total hip arthroplasties during which the cemented monobloc femoral component has been systematically revised.

MATERIALS AND METHODS

We performed 22 revisions of both components of Charnley type cemented total hip arthroplasties. In all cases, the 22.2 mm head of the monobloc femoral component was made of 316 L stainless steel. The international standard for such femoral heads includes an average surface roughness (Ra) of 0.05 microm, a total roughness (Rt) value of 0.5 microm and a sphericity of +/-5 microm. The mean age of the patients at the time of the index arthroplasty was 51.3 years. The average time to revision was 14.8 years (seven to 25 years). The reasons for revision included isolated socket loosening (12), extensive periacetabular osteolysis without socket loosening (two), recurrent dislocation associated with socket loosening (one), sepsis without implant loosening (one), loosening of both components (one), and isolated loosening of the femoral component (five). Hence, 15 of the 22 (68.2%) femoral components could theoretically have been retained. The surface roughness of the femoral heads was evaluated using a contact-type profilometer. For each head, the apex and two zones, either macroscopically scratched or with loss of the mirror finish, were analyzed. Moreover, the sphericity of the heads was measured using a spherometer.

RESULTS

The stem explanted after recurrent dislocation was analyzed separately as the femoral head had major scratches. The mean Ra and Rt of the series at the apex was 0.029 and 0.876 microm, respectively. The mean Ra and Rt of the series for the macroscopically damaged areas was 0.05 microm and 1.540 microm, respectively. The mean sphericity of the series was 7.2 microm. Hence among the 22 explanted stems, 10 femoral heads (45.4%) had Ra or Rt apex and 18 (81.8%) Ra or Rt scratched area values beyond ISO standards, respectively. Sphericity was greater than +/-5mm for 13 of the 22 femoral heads (59.1%). With the numbers available, the age at the time of the index arthroplasty, the BMI, the time and the reason for revision were not significantly associated with the degree of femoral head damage for both roughness and sphericity parameters.

DISCUSSION

Retaining the femoral component during revision of the total hip arthroplasty including a monobloc femoral component is theoretically an interesting alternative. However, femoral head surface damage occurring in vivo would have lead us to retain severely scratched heads in over 80% of the hips, and heads with abnormal roughness and sphericity values in over 90% of the hips. Bases upon our results, we recommend systematically revising the femoral component during revision THA including a monobloc stem, irrespective of the reason for revision.

Nonidentical and outlier duty cycles as factors accelerating UHMWPE wear in THA: a finite element exploration

Wear rate and wear direction vary considerably within total hip arthroplasty (THA) patient cohorts. Third body effects and wide-ranging differences in patient activity levels are two factors suspected of contributing to wear variability. A sliding-distance-coupled contact finite element formulation was used to test the hypothesis that nonidentical duty cycles (differing activities, or change of third body challenge) produce accelerations in polyethylene wear. Effects of nonidentical duty cycles, time-variant femoral head roughening, and outlier gait inputs were investigated. Without femoral head roughening, combination walk/stair-climb wear simulations did not result in appreciably higher volumetric wear than a walk-only simulation, but when a roughened zone was included, walk/stair-climb volumetric wear increased by approximately 57% above that of a similarly roughened walk-only simulation. To investigate time-variant femoral head roughening, wear simulations were begun with femoral head roughening at one location on the femoral head, switching to another location halfway through the simulation. Results varied depending on roughening sites, but cases of substantial increase in wear involved a transient jump in wear rate shortly after the change of head roughening location. Outlier duty cycles were simulated by increasing or decreasing the joint contact force and range of motion inputs, to levels at the 97.5th and 2.5th percentiles of a population of normal subjects. The resulting wear showed an increase or decrease closely proportional to the percentage by which each input (force or range of motion) was changed.

The effect of total hip arthroplasty cup design on polyethylene wear rate

Using 743 total hip arthroplasties that included 6 hemispheric porous-coated cup designs, this study used a multiple linear regression to identify those factors that influenced polyethylene wear rates. Wear rates for each hip were based on serial head penetration measurement made with computer-assisted techniques. Implant factors associated with an increased wear rate included terminal sterilization with a non-cross-linking chemical surface treatment, a 4-mm lateralized liner, a cobalt-chrome femoral head, and a longer shelf life for liners gamma-irradiated in air. After accounting for these implant characteristics and patient factors, wear rates among the 6 cup designs were not significantly different (P = .89). Although polyethylene wear is frequently characterized for specific implant designs, this study demonstrated that there are several common factors that influence polyethylene wear rates.

Assessing the pattern of femoral head penetration after total hip arthroplasty

We evaluated temporal changes in wear rates among 205 primary cementless total hip arthroplasties that had minimum 10-year follow-up and at least 6 follow-up x-rays. Using the pelvic anteroposterior x-rays from each hip, two-dimensional head penetration was measured and wear rates were calculated using several techniques. The average wear rate for the study population did not demonstrate evidence of accelerated wear at 10- to 18-year follow-up. As an increasing number of follow-up x-rays were included in the least-squares linear regression used to calculate the wear rate, the 95% confidence interval associated with the wear rate for an individual hip tended to progressively decrease. These results indicate that a constant wear rate is a reasonable assumption for modeling clinical wear data. Although we cannot quantify the effects of polyethylene oxidation, femoral head roughening, debris accumulation, or activity level changes, the combination of these factors is not leading to clinically perceptible accelerated wear at intermediate to long-term follow-up in this heterogeneous population of cups representing our institutional experience.

Mechanisms of failure of total hip replacements: lessons learned from retrieval studies

The value of implant retrieval analysis in orthopaedic surgery has been well recognized. Prosthetic devices retrieved for cause at revision surgery (for implant failure) or devices retrieved postmortem from patients with clinically successful reconstructions provide a unique set of specimens that can be studied to evaluate the effect of the implant on the host environment and the effect of the host environment on the implant. A systematic analysis of retrieved components, in combination with histologic, radiographic, and clinical data can provide valuable insights into the mechanisms of failure of the biomaterials used in joint replacement applications. From the hip implant retrieval studies reported to date, it has been established that the local reaction to particulate wear debris initiates the formation of a granulomatous tissue that ultimately invades the bone-implant interface and results in aseptic loosening. Cement mantle defects, noncircumferential porous coatings, and screw holes can serve as preferential access pathways for the progression of this granulomatous process yielding distinctive patterns of implant loosening and osteolysis. Continued surveillance of retrieved devices is strongly recommended to deepen our understanding of implant failure mechanisms and to evaluate the impact of newer designs and materials on the performance of joint replacement devices.

Correlation between early and late wear rates in total hip arthroplasty with application to the performance of marathon cross-linked polyethylene liners

Laboratory simulations are typically used to assess the performance of new bearing surfaces for total hip arthroplasty. However, the ability of in vitro studies to accurately predict clinical wear performance remains uncertain. Using computer-assisted radiographic measurement techniques, this study found that the average wear rate based on early (2-3 years) clinical follow-up is representative of the average long-term wear rate for a population. Based on early wear data, Marathon polyethylene liners, cross-linked with 5.0 Mrad of gamma irradiation, are wearing at a mean rate of 0.08 mm/yr. This rate is about half that of non-cross-linked polyethylene but represents a more modest wear reduction than in vitro studies have predicted. If 5 to 10-year Marathon wear data corroborate our short-term results, early clinical wear data should be used to validate hip simulator studies.

Normal and prosthetic synovial joints are lubricated by surface-active phospholipid: a hypothesis

Much evidence supports the hypothesis that surface-active phospholipid (SAPL), which imparts the thin hydrophobic outermost lining to the normal articular surface, is the boundary lubricant reducing friction to remarkably low levels. We review this evidence and further hypothesize that SAPL produced in type B synoviocytes will also lubricate prostheses after implantation. This could explain why implanted hips display far less wear than hips in simulated wear trials do, even using protein as the lubricant whereas rougher surfaces can be tolerated in vivo. We introduce the concept that a deficiency of SAPL might explain the selective failure of prostheses just as osteoarthritic articular surfaces are deficient. This, in turn, leads to the replenishment of SAPL, as tested in OA, and the concept of prelubricating prostheses before implantation.

Effect of counterface roughness on the wear of conventional and crosslinked ultrahigh molecular weight polyethylene studied with a multi-directional motion pin-on-disk device

The effect of counterface roughness on the wear of conventional gamma-sterilized, and electron-beam-crosslinked ultrahigh molecular weight polyethylene was studied with a circularly translating pin-on-disk device. The counterfaces, CoCr disks, were either polished, or roughened so that they represented the type of roughening and the range of surface roughness values (R(a) = 0.014-0.24 microm) observed in explanted femoral heads of total hip prostheses. The lubricant was diluted calf serum, and the test length 3 million cycles. A total of 24 tests were done. With both types of polyethylene, there was a strong correlation between R(a) and wear factor k. The power equations were k = 5.87 x 10(-5)(R(a))(0.91) for conventional polyethylene (R(2) = 0.94), and k = 7.87 x 10(-5)(R(a))(2.49) for crosslinked polyethylene (R(2) = 0.82). Crosslinking improved wear resistance significantly. The wear of crosslinked polyethylene against the roughest counterfaces was lower than the wear of conventional polyethylene against the polished counterfaces. Against rough counterfaces, the wear of crosslinked polyethylene was an order of magnitude lower than that of conventional polyethylene. On the crosslinked polyethylene pins that were tested against polished counterfaces, remains of original machining marks were still visible after the test. The average size of wear particles produced by both types of polyethylene against rough counterfaces was similar, 0.4 microm, whereas that produced by conventional and crosslinked polyethylene against polished counterfaces was significantly smaller, 0.2 and 0.1 microm, respectively.

The effect of femoral head diameter upon lubrication and wear of metal-on-metal total hip replacements

It has been found that a remarkable reduction in the wear of metal-on-metal hip joints can be achieved by simply increasing the diameter of the joint. A tribological evaluation of metal-on-metal joints of 16, 22.225, 28 and 36 mm diameter was conducted in 25 per cent bovine serum using a hip joint simulator. The joints were subject to dynamic motion and loading cycles simulating walking for both lubrication and wear studies. For each size of joint in the lubrication study, an electrical resistivity technique was used to detect the extent of surface separation through a complete walking cycle. Wear of each size of joint was measured gravimetrically in wear tests of at least 2 x 10(6) cycles duration. Joints of 16 and 22.225 mm diameter showed no surface separation in the lubrication study. This suggested that wear would be proportional to the sliding distance and hence joint size in this boundary lubrication regime. A 28 mm diameter joint showed only limited evidence of surface separation suggesting that these joints were operating in a mixed lubrication regime. A 36 mm diameter joint showed surface separation for considerable parts of each walking cycle and hence evidence of the formation of a protective lubricating film. Wear testing of 16 and 22.225 mm diameter metal-on-metal joints gave mean wear rates of 4.85 and 6.30 mm3/10(6) cycles respectively. The ratio of these wear rates, 0.77, is approximately the same as the joint diameters ratio, 16/22.225 or 0.72, as expected from simple wear theory for dry or boundary lubrication conditions. No bedding-in was observed with these smaller diameter joints. For the 28 mm diameter joint, from 0 to 2 x 10(6) cycles, the mean wear rate was 1.62 mm3/10(6) cycles as the joints bedded-in. Following bedding-in, from 2.0 x 10(6) to 4.7 x 10(6) cycles, the wear rate was 0.54 mm3/10(6) cycles. As reported previously by Goldsmith et al. in 2000 [1], the mean steady state wear rate of the 36 mm diameter joints was lower than those of all the other diameters at 0.07 mm3/10(6) cycles. For a range of joints of various diameters, subjected to identical test conditions, mean wear rates differed by almost two orders of magnitude. This study has demonstrated that the application of sound tribological principles to prosthetic design can reduce the wear of metal-on-metal joints, using currently available materials, to a negligible level.