How do alternative bearing surfaces influence wear behavior?

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.

Material Science in Cervical Total Disc Replacement

Current cervical total disc replacement (TDR) designs incorporate a variety of different biomaterials including polyethylene, stainless steel, titanium (Ti), and cobalt-chrome (CoCr). These materials are most important in their utilization as bearing surfaces which allow for articular motion at the disc space. Long-term biological effects of implanted materials include wear debris, host inflammatory immune reactions, and osteolysis resulting in implant failure. We review here the most common materials used in cervical TDR prosthetic devices, examine their bearing surfaces, describe the construction of the seven current cervical TDR devices that are approved for use in the United States, and discuss known adverse biological effects associated with long-term implantation of these materials. It is important to appreciate and understand the variety of biomaterials available in the design and construction of these prosthetics and the considerations which guide their implementation.

Profiling the third-body wear damage produced in CoCr surfaces by bone cement, CoCr, and Ti6Al4V debris: A 10-cycle metal-on-metal simulator test

Particles of bone cement (polymethyl methacrylate), CoCr and Ti6Al4V were compared for their abrasion potential against CoCr substrates. This appears to be the first study utilizing CoCr and Ti6Al4V particulates to abrade CoCr bearings and the first study profiling the morphology of third-body abrasive wear scratches in a hip simulator. The 5 mg debris allotments (median size range 140–300 µm) were added to cups mounted both inverted and anatomically with metal-on-metal (MOM) bearings in a 10-cycle, hip simulator test. Surface abrasion was characterized by roughness indices and scratch profiles. Compared to third-body abrasion with metal debris, polymethyl methacrylate debris had minimal effect on the CoCr surfaces. In all, 10 cycles of abrasion with metal debris demonstrated that roughness indices (Ra, PV) increased approximately 20-fold from the unworn condition. The scratch profiles ranged 20–108 µm wide and 0.5–2.8 µm deep. The scratch aspect ratio (W/PV) averaged 0.03, and this very low ratio indicated that the 140 µm CoCr beads had plastically deformed to create wide but shallow scratches. There was no evidence of transfer of CoCr beads to CoCr bearings. The Ti64 particles produced similar scratch morphology with the same aspect ratio as the CoCr particulates. However, the titanium particulates also showed a unique ability to flatten and adhere to the CoCr, forming smears and islands of contaminating metal on the CoCr bearings. The morphology of scratches and metal transfer produced by these large metal particulates in the simulator appeared identical to those reported on retrieved metal-on-metal bearings.

Risk of impingement and third-body abrasion with 28-mm metal-on-metal bearings

BACKGROUND

Concerns have been raised about the sequelae of metal-on-metal (MoM) bearings in total hip arthroplasty (THA). However, retrieval studies, which offer the best insight into the clinically relevant mechanisms of MoM wear, have followed predictable trends to date such as indicting cobalt-chromium (CoCr) metallurgy, cup design, high conformity between the head and cup, "steep cups," "microseparation," and "edge wear."

QUESTIONS/PURPOSES

We wished to evaluate a set of retrieved 28-mm MoM THA for signs of (1) cup-to-stem impingement; (2) normal wear pattern and concomitant stripe damage on femoral heads that would signify adverse wear mechanics; and (3) well-defined evidence of third-body scratches on bearings that would indicate large abrasive particles had circulated the joint space.

METHODS

Ten 28-mm MOM retrievals were selected on the basis that femoral stems were included. Revision surgeries at 3 to 8 years were for pain, osteolysis, and cup loosening. CoCr stems and the MoM bearings were produced by one vendor and Ti6Al4V stems by a second vendor. All but two cases had been fixed with bone cement. We looked for patterns of normal wear and impingement signs on femoral necks and cup rims. We looked for adverse wear defined as stripe damage that was visually apparent on each bearing. Wear patterns were examined microscopically to determine the nature of abrasions and signs of metal transfer. Graphical models recreated femoral neck and cup designs to precisely correlate impingement sites on femoral necks to cup positions and head stripe patterns.

RESULTS

The evidence revealed that all CoCr cup liners had impinged on either anterior or posterior facets of femoral necks. Liner impingement at the most proximal neck notch occurred with the head well located and impingement at the distal notch occurred with the head rotated 5 mm out of the cup. The hip gained 20° motion by such a subluxation maneuver with this THA design. All heads had stripe wear, the basal and polar stripes coinciding with cup impingement sites. Analysis of stripe damage revealed 40 to 100-μm wide scratches created by large particles ploughing across bearing surfaces. The association of stripe wear with evidence of neck notching implicated impingement as the root cause, the outcome being the aggressive third-body wear.

CONCLUSIONS

We found consistent evidence of impingement, abnormal stripe damage, and evidence of third-body abrasive wear in a small sample of one type of 28-mm MoM design. Impingement models demonstrated that 28-mm heads could lever 20° out of the liners. Although other studies continue to show good success with 28-mm MoM bearings, their use has been discontinued at La Pitie Hospital.

The 2012 Frank Stinchfield Award: Decreasing patient activity with aging: implications for crosslinked polyethylene wear

BACKGROUND

Patient activity influences polyethylene wear. However, it is unclear how individual activity changes with patient aging after THA.

QUESTIONS/PURPOSES

We quantified changes in individual gait cycles and gait speed, assessed age-related differences in these parameters, and determined their relationship to polyethylene wear.

METHODS

A microprocessor was worn on the ankle to quantify the activity of 14 healthy patients with a well-functioning THA at two time periods: early (within 3.5 years of implantation) and late (10-13 postoperative years). Wear was measured on serial radiographs using edge detection-based software.

RESULTS

Mean activity decreased by 16% from the early to the late period: 2.04 million gait cycles/year to 1.71 million gait cycles/year. Mean gait speed decreased by 9%: 15.4 cycles/minute to 14.0 cycles/minute. The activity of the 10 patients who were younger than 65 years at surgery decreased by 14% (2.34 million gait cycles/year to 2.02 million gait cycles/year), while the four patients 65 years or older at surgery decreased by 28% (1.29 million gait cycles/year to 0.94 million gait cycles/year). Gait speed was 26% slower for patients 65 years or older than for patients younger than 65 years. The mean linear penetration rate decreased by 42% from the first 5 years (early wear rate) to the next 8 years (late wear rate, 5-13 years): 0.043 mm/year to 0.025 mm/year.

CONCLUSIONS

The greatest patient activity and wear occurred during the first 5 years. Walking speed and gait cycles both decreased with aging, resulting in deceasing wear over time.

Effects of design parameters of total hip components on the impingement angle and determination of the preferred liner skirt shape with an adequate oscillation angle

The oscillation angle (OsA), which is the sum of the impingement angles on the two sides when the prosthetic neck sways from the neutral axis of the acetabular cup to the liner rim, is one of the most important factors that can affect the range of motion of an artificial hip joint. The aim of this study was to determine the influence of total hip component design on the impingement angle. Our findings show that an increase in cup depth of the liner restricts the motion of the neck and results in a reduced impingement angle, while an increase in chamfer angle increases the impingement angle until it reaches a critical value when a further increase no longer results in an increase in impingement angle. The impingement angle is not only dependent on the head/neck ratio, but also on the head size itself. For most arbitrarily chosen cup depths and chamfer angles, the neck only impacts at one point on the liner. This study proposes a suitable combination of cup depth and chamfer angle and a preferred impact mode, which, if impingement does occur, enables the neck to impinge on the liner rim over a large area. Cup-neck combinations that have an adequate OsA with maximum femoral head coverage are presented.

Ideal femoral head size in total hip arthroplasty balances stability and volumetric wear

BACKGROUND

Over the last several years, a trend towards increasing femoral head size in total hip arthroplasty to improve stability and impingement free range of motion has been observed.

PURPOSE

The specific questions we sought to answer in our review were: (1) What are the potential advantages and disadvantages of metal-on-metal, ceramic-on-ceramic, and metal-on-polyethylene bearings? (2) What is effect that femoral head size has on joint kinematics? (3) What is the effect that large femoral heads have on bearing surface wear?

METHODS

A PubMed search and a review of 2012 Orthopaedic Research Society abstracts was performed and articles were chosen that directly answered components of the specific aims and that reported outcomes with contemporary implant designs or materials.

RESULTS

A review of the literature suggests that increasing femoral head size decreases the risk of postoperative dislocation and improves impingement free range of motion; however, volumetric wear increases with large femoral heads on polyethylene and increases corrosion of the stem in large metal-on-metal modular total hip arthroplasty (THA); however, the risk of potentially developing osteolysis or adverse reactions to metal debris respectively is still unknown. Further, the effect of large femoral heads with ceramic-on-ceramic THA is unclear, due to limited availability and published data.

CONCLUSIONS

Surgeons must balance the benefits of larger head size with the increased risk of volumetric wear when determining the appropriate head size for a given patient.

Bearing surfaces for total disc arthroplasty: metal-on-metal versus metal-on-polyethylene and other biomaterials

BACKGROUND CONTEXT

Concerns about the effect of metallic wear debris from metal-on-metal bearing surfaces in total hip arthroplasty have increased. Some spinal arthroplasty devices include metal-on-metal bearing surfaces.

PURPOSE

To review the literature for clinical reports of complications because of wear debris from metal-on-metal spinal arthroplasty devices. To review the biology of wear debris from metal-on-metal bearing surfaces drawn from the hip arthroplasty literature and place it in the context of global regulatory actions and clinical and laboratory studies.

STUDY DESIGN

Literature review.

METHODS

To identify clinical reports, the PubMed database from the United States National Library of Medicine was queried using Medical Subject Headings terms and additional keyword terms. In addition, experts from academia and regulatory agencies were questioned regarding their knowledge of reports, including experts who attended the US Food and Drug Administration roundtable in September 2010.

RESULTS

Three case reports and one case series including seven total cases were identified in which abnormal inflammatory reactions and soft-tissue masses after metal-on-metal disc replacements were consistent with pseudotumor and metal hypersensitivity. Spinal cases are present as pain and neurologic symptoms. On plain radiography, there is no clear periprosthetic osteolysis or loosening. On magnetic resonance imaging, there is increased magnetic susceptibility artifact because of metallic debris that renders images inadequate. Computed tomography myelography demonstrates a soft-tissue mass, which exhibits epidural extension surgically. Histologically, large areas of necrotic debris and exudates are interspersed with chronic inflammatory cells. Lymphocyte or macrophage predominance is determined by the rate of wear and the presence of gross, microscopic, or submicron metallic wear debris. The metallurgy of the involved devices is cobalt-chromium-molybdenum (CoCrMo) alloy, and the bearing surface is CoCrMo-on-CoCrMo.

CONCLUSIONS

Metal-on-metal spinal arthroplasty devices are subject to postoperative complications because of metallic wear debris with similar clinical, radiographic, histologic, gross anatomic, and device-related features to those found in metal-on-metal bearing surfaces in total hip arthroplasty.

Squeaking in third- and fourth-generation ceramic-on-ceramic total hip arthroplasty: meta-analysis and systematic review

Postoperative squeaking in ceramic-on-ceramic total hip arthroplasty is a recently emerging phenomenon. We performed a meta-analysis of published data to examine patient and procedural risk factors. Twelve studies (6137 patients, total) were analyzed, with 150 patients (2.4%) complaining of squeaking. The only significant patient risk factor was increasing body mass index (P = .03, n = 2957). There was no significance found with patient age, sex, height, weight, or procedural laterality for squeak incidence. For implant type, the presence of a Stryker Accolade femoral stem (beta-titanium; Stryker Orthopedics, Mahwah, NJ) was significantly found to increase squeak (P < .0001, n = 4654). The presence of a raised metallic lip on the acetabular component was not found to be associated with squeak. Acetabular cup position was also not found to have a significant bearing on the incidence of squeaking.

Wear degradation of long-term in vivo exposed alumina-on-alumina hip joints: linking nanometer-scale phenomena to macroscopic joint design

The wear behavior of alumina femoral heads was examined at follow-up periods between 7.7 and 10.7 years. Four head retrievals of the same size (28 mm in diameter) were divided into two groups with different design characteristics. Systematically using scanning electron and atomic force microscopy procedures, wear characteristics could be classified on the entire heads according to five zones with increasing degrees of wear damage (Grade 1-5), in addition to one zone of stripe wear (Grade SW). The stripe wear zone showed quite different topographical features as compared to frictionally worn zones. Furthermore, hip implants designed with different clearances are shown to lead to different wear patterns on the femoral head surface, the smaller the clearance the wider the worn surface area. Cathodoluminescence piezo-spectroscopy provided information about the residual stress state in surfaces worn to different degrees and helped clarifying the wear mechanisms on the microscopic scale.

Wear analysis of chamfered elongated acetabular cup liners

This study investigated the wear phenomena of chamfered acetabular cup liners. The liners have three parameters at the lengthened rim: the length of the elongation, the depth of the cup and the chamfer angle. Using published wear volume equations for cylindrically elongated liners, this study analysed the volume of the chamfer to obtain the exact theoretical wear volume of the chamfered liner. The criteria described in our previous paper were used to verify the accuracy of the proposed methodology. The results showed that a shallow cup depth (<2 mm) and a chamfer angle of about 30° could significantly reduce the wear volume arising from the elongation. When the chamfer angle was increased further, this effect became progressively less significant. The results suggest that a chamfer angle up to about 30° is appropriate, but the angle should not be larger than required to obtain the minimum femoral range of motion (ROM). The results of this study can also be integrated with the analysis of the kinetics and kinematics of liners. A compromise design incorporating a lower wear volume, sufficient ROM and a lower contact stress should be possible.

Is metal-on-metal squeaking related to acetabular angle of inclination?

BACKGROUND

Postoperative audible squeaking has been well documented in ceramic-on-ceramic hip prostheses, and several metal-on-metal (MOM) THA designs, specifically those used for large-head resurfacing and MOM polyethylene sandwich designs, and are attributed to different implant- and patient-specific factors. Current literature does not identify the incidence of squeaking in modular MOM THA or possible etiologic factors.

QUESTIONS/PURPOSES

Our purposes were to (1) identify the incidence of squeaking in modular MOM prostheses in THA; (2) determine whether males or females were more likely to have squeaking; and (3) determine whether the incidence of squeaking relates to acetabular inclination angle.

METHODS

We retrospectively reviewed the patient records and radiographs of 539 patients (542 hips) from three independent centers who underwent a MOM THA between February 2001 and December 2005. Demographic and implant factors were evaluated, including measurement of cup inclination angles. The minimum followup was 36 months (mean, 76 months; range, 36-119 months).

RESULTS

We identified squeaking in eight of the 542 hips (1.5%); five were in women and two were in men (one patient had bilateral squeaking). The time to onset of patient-reported audible squeaking averaged 23 months (range, 6-84 months). Squeaking was more likely to occur in women (six of eight hips). No hips with 45º or less acetabular inclination squeaked (291 hips); eight of 251 hips (3.2%) with inclination angles greater than 45º squeaked. Patients who reported squeaking had higher inclination angles than those who did not report squeaking.

CONCLUSIONS

Our observations suggest an increased frequency of squeaking in female patients and in patients with greater inclination angles with this MOM implant design.

A review of squeaking hips

The incidence of squeaking in hip replacement varies for ceramic-on-ceramic and metal-on-metal bearings, and the implications are not fully understood. Contributing factors may include component malposition, edge loading, impingement, third-body particles, and loss of lubrication. However, squeaking is multifactorial, requiring a certain combination of interaction among patient, surgical, and implant factors. When squeaking is infrequent and function is not impaired, patients should avoid activities that precipitate the squeaking. Surgery is recommended for persistent or troublesome squeaking, severe malpositioning of components, failure of the implants (including fracture), impingement and subluxation, and pain. If necessary, the bearing can be changed during surgery to another ceramic-on-ceramic or to a ceramic-on-polyethylene bearing.

Wear patterns of, and wear volume formulae for, cylindrically elongated acetabular cup liners

This study analyzed the wear patterns of, and wear volume formulae for, cylindrically elongated acetabular cup liners. The geometric patterns of the wear surface were first classified, then wear volume formulae were derived by integral calculus. SolidWorks((R)) software or published formulae were used to verify the accuracy of the proposed formulae. The analytical results showed that the wear shape of the liner can be categorized into seven wear patterns, including the special case of wear at 90 degrees , and the seven corresponding wear formulae were derived. In addition, wear of the cylindrical elongation might add considerably to the volume loss of the liner, depending on the height and shape of the elongation and the depth and direction of the linear penetration, being maximally 21% in the investigated model. The proposed wear formulae and patterns will be useful for more accurate performance evaluation of existing hip components implanted in patients and for the designing of new hip components.

Incidence of 'squeaking' after ceramic-on-ceramic total hip arthroplasty

The incidence of hip "squeak" associated with ceramic-on-ceramic bearings has been variably reported, ranging from 0.7% to 20.9%. We determined the patients' perception of squeaking in 306 patients (336 hips) in whom ceramic-on-ceramic total hip arthroplasties (THAs) were performed between 1997 and 2005. A questionnaire regarding hip noise was obtained by telephone. With a minimum followup of 2 years (mean, 3.9 years; range, 2-10 years), 290 patients (320 or 95% of the THAs) completed the questionnaire. Patients reported hip noise in 55 of the 320 THAs (17%); noise was perceived as squeak in 32 of the 320 (10%). Most squeaking hips (29 of 32) were pain-free and symptom-free. One patient was unhappy with his squeaking hip without pain. Our data suggest a much higher incidence of squeak as perceived by patients than previously reported.

LEVEL OF EVIDENCE

Level II, therapeutic study. See Guidelines for Authors for a complete description of levels of evidence.