1
|
Wu T, Guo S, Jiang Y, Shi W, Wang Y, Li T. Ceramic fragmentation after total hip arthroplasty: two case reports and literature review. Front Surg 2024; 11:1357301. [PMID: 38444899 PMCID: PMC10912464 DOI: 10.3389/fsurg.2024.1357301] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/17/2023] [Accepted: 02/09/2024] [Indexed: 03/07/2024] Open
Abstract
Background Ceramic fragmentation is a rare but serious complication after total hip arthroplasty (THA). We reviewed the PubMed literature from 1990 to 2023 and found only 31 case reports of ceramic fragmentation after THA. Our case reports help to expand understanding of this rare complication. We shared our surgical experience and identified an ideal material for revision surgery, which can serve as a useful reference for other orthopedic surgeons to perform ceramic fragmentation revision surgery in the future. We also analyzed the possible causes, diagnosis, and treatment opinions of ceramic fragmentation. Case presentation This study presents two cases of ceramic fragmentation after THA. One patient had ceramic head fragmentation 10 years after the primary THA, and one patient had ceramic liner fragmentation 5 years after the primary THA. Both patients presented with pain, and one patient also reported a clicking sound in the hip. The two patients described here had BMIs of 23.7 and 23.1, respectively. Both patients' ceramic fragmentation were due to aseptic loosening, not periprosthetic joint infections, as confirmed by negative microbiological cultures. Radiographic examinations of both patients revealed radio-opaque wear debris around the hip joint prostheses and we describe the surgical protocols and intraoperative findings in both cases in detail. Conclusion Our cases and the literature suggest that ceramic fragmentation can occur at any time after THA. The most immediate symptoms are pain and noise, but some patients may be asymptomatic. Ceramic on polyethylene bearings is recommended for revision surgery whenever possible; metal bearings should be avoided.
Collapse
Affiliation(s)
- Tingyu Wu
- Department of Joint Surgery, The Affiliated Hospital of Qingdao University, Qingdao, China
| | - Sijia Guo
- Department of Joint Surgery, The Affiliated Hospital of Qingdao University, Qingdao, China
| | - Yaping Jiang
- Department of Oral Implantology, The Affiliated Hospital of Qingdao University, Qingdao, China
| | - Weipeng Shi
- Department of Joint Surgery, The Affiliated Hospital of Qingdao University, Qingdao, China
| | - Yingzhen Wang
- Department of Joint Surgery, The Affiliated Hospital of Qingdao University, Qingdao, China
| | - Tao Li
- Department of Joint Surgery, The Affiliated Hospital of Qingdao University, Qingdao, China
| |
Collapse
|
2
|
Döring J, Buchholz A, Herbster M, Gehring J, Betke U, Chodór P, Zabrzyński J, Bertrand J, Lohmann CH, Łapaj Ł. Damage analysis of retrieved Biolox Ⓡdelta components used in hard and soft bearings. Acta Biomater 2023; 158:827-842. [PMID: 36599400 DOI: 10.1016/j.actbio.2022.12.055] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/07/2022] [Revised: 12/21/2022] [Accepted: 12/23/2022] [Indexed: 01/02/2023]
Abstract
This retrieval study included 43 Biolox delta explants (18 CoC, 25 CoP). Implants were examined macroscopically, whereby damage was evaluated using a semi quantitative scoring system. Confocal microscopy was used to examine wear related damage patterns of the articulating surfaces. Scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS) was used to analyze wear marks on the implant surface and wear debris in periprosthetic tissue samples. Raman spectroscopy and X-ray diffraction (XRD) were used to quantify monoclinic zirconia fractions. On all components, in vivo wear resulted predominantly in different damage patterns caused by metal transfer. In CoC bearings stripe wear was additionally detected, and some implants underwent severe damage due to component breakage. The wear scores were higher for CoC components, with no differences between the scores for CoC heads and liners. Wear features caused comparable roughening on implants from CoC and CoP bearings. SEM studies demonstrated that most wear marks were caused by metal debris released from implant components. Grain pull-out was observed in stripe wear regions. Monoclinic phase shift was observed in a similar quantity on components from CoP and CoC bearings. The increase of monoclinic zirconia content around metal deposits was minimal and was more pronounced in areas of stripe wear. The results of this study indicate, that ZTA components in general undergo minimal wear in both, CoC and CoP bearings, however, it is more pronounced in the former. Metal deposits, as the most common wear feature, have no significant effect on monoclinic phase transition. STATEMENT OF SIGNIFICANCE: In this paper, we classify all damage patterns macroscopically according to an established scoring system and assess them regarding surface roughness (confocal microscopy) and monoclinic phase content (Raman spectroscopy) in order to derive the severity for patients. We compare hard-hard and hard-soft bearings and relate damage patterns with metal transfer based on SEM/EDS examinations. Furthermore, we work out correlations between patient-specific data, cause of revision and the physical condition of each individual sample Our cohort consists of 43 Biolox delta retrievals, a comparatively large quantity. In addition, we address current topics such as metal transfer and, based on the classification of damage patterns, provide incentives and/or meaningful focal points for further research.
Collapse
Affiliation(s)
- Joachim Döring
- Department of Orthopaedic Surgery, Otto-von-Guericke-University, Magdeburg, Germany.
| | - Adrian Buchholz
- Department of Orthopaedic Surgery, Otto-von-Guericke-University, Magdeburg, Germany
| | - Maria Herbster
- Institute of Materials and Joining Technology, Otto-von-Guericke-University, Magdeburg, Germany
| | - Jennifer Gehring
- Department of Orthopaedic Surgery, Otto-von-Guericke-University, Magdeburg, Germany
| | - Ulf Betke
- Institute of Materials and Joining Technology, Otto-von-Guericke-University, Magdeburg, Germany
| | - Paweł Chodór
- Department of General Orthopaedics, Musculoskeletal Oncology and Trauma Surgery, Poznań, Poland
| | - Jan Zabrzyński
- Faculty of Medicine, Nicolas Copernicus University, Toruń, Collegium Medicum in Bydgoszcz, Poland
| | - Jessica Bertrand
- Department of Orthopaedic Surgery, Otto-von-Guericke-University, Magdeburg, Germany
| | - Christoph H Lohmann
- Department of Orthopaedic Surgery, Otto-von-Guericke-University, Magdeburg, Germany
| | - Łukasz Łapaj
- Department of General Orthopaedics, Musculoskeletal Oncology and Trauma Surgery, Poznań, Poland
| |
Collapse
|
3
|
Lucchini S, Baleani M, Giardina F, Martelli A, Castagnini F, Bordini B, Traina F. A case-driven hypothesis for multi-stage crack growth mechanism in fourth-generation ceramic head fracture. J Orthop Surg Res 2022; 17:293. [PMID: 35658905 PMCID: PMC9164427 DOI: 10.1186/s13018-022-03190-6] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Received: 04/07/2022] [Accepted: 05/13/2022] [Indexed: 11/10/2022] Open
Abstract
BACKGROUND Ceramic bearings are used in total hip arthroplasty due to their excellent wear behaviour and biocompatibility. The major concern related to their use is material brittleness, which significantly impacts on the risk of fracture of ceramic components. Fracture toughness improvement has contributed to the decrease in fracture rate, at least of the prosthetic head. However, the root cause behind these rare events is not fully understood. This study evaluated head fracture occurrence in a sizeable cohort of patients with fourth-generation ceramic-on-ceramic implants and described the circumstances reported by patients in the rare cases of head fracture. METHODS The clinical survivorship of 29,495 hip prostheses, with fourth-generation ceramic bearings, was determined using data from a joint replacement registry. The average follow-up period was 5.2 years (range 0.1-15.6). Retrieval analysis was performed in one case for which the ceramic components were available. RESULTS Clinical outcomes confirmed the extremely low fracture rate of fourth-generation ceramic heads: only two out of 29,495 heads fractured. The two fractures, both involving 36 mm heads, occurred without a concurrent or previous remarkable trauma. Considering the feature of the fractured head, a multi-stage crack growth mechanism has been hypothesized to occur following damage at the head-neck taper interface. CONCLUSIONS Surgeons must continue to pay attention to the assembly of the femoral head: achieving a proper head seating on a clean taper is a prerequisite to decrease the risk of occurrence of any damage process within head-neck junction, which may cause high stress concentration at the contact surface, promoting crack nucleation and propagation even in toughened ceramics.
Collapse
Affiliation(s)
- Stefano Lucchini
- IRCCS Istituto Ortopedico Rizzoli, Ortopedia-Traumatologia e Chirurgia Protesica e dei Reimpianti d'Anca e Ginocchio, Bologna, Italy
| | - Massimiliano Baleani
- IRCCS Istituto Ortopedico Rizzoli, Laboratorio di Tecnologia Medica, Bologna, Italy.
| | - Federico Giardina
- IRCCS Istituto Ortopedico Rizzoli, Ortopedia-Traumatologia e Chirurgia Protesica e dei Reimpianti d'Anca e Ginocchio, Bologna, Italy
| | - Andrea Martelli
- IRCCS Istituto Ortopedico Rizzoli, Laboratorio di Tecnologia Medica, Bologna, Italy
| | - Francesco Castagnini
- IRCCS Istituto Ortopedico Rizzoli, Ortopedia-Traumatologia e Chirurgia Protesica e dei Reimpianti d'Anca e Ginocchio, Bologna, Italy
| | - Barbara Bordini
- IRCCS Istituto Ortopedico Rizzoli, Laboratorio di Tecnologia Medica, Bologna, Italy
| | - Francesco Traina
- IRCCS Istituto Ortopedico Rizzoli, Ortopedia-Traumatologia e Chirurgia Protesica e dei Reimpianti d'Anca e Ginocchio, Bologna, Italy
| |
Collapse
|
4
|
Dobria P, Patel A, Levine B. Catastrophic intraoperative failure of a ceramic femoral head. Arthroplast Today 2021; 11:234-238. [PMID: 34692961 PMCID: PMC8515067 DOI: 10.1016/j.artd.2021.08.017] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Received: 06/23/2021] [Revised: 08/04/2021] [Accepted: 08/29/2021] [Indexed: 11/18/2022] Open
Abstract
Approximately 17 years after a primary metal-on-metal total hip arthroplasty, a 59-year-old female developed pain, swelling, and weakness in her right hip accompanied by laboratory findings and imaging suggestive of an adverse local tissue reaction. Acetabular revision was performed to upsize the femoral head and improve hip stability. Upon impaction of the new, non-option ceramic femoral head onto the unsleeved retained stem, the head split into two pieces without fragmentation. The surgery was completed using a cobalt-chromium head, which was impacted without issue onto the stem’s taper. Although BIOLOX delta femoral heads do not require titanium sleeves, we believe that careful consideration should be given to their use in revision total hip arthroplasty with ceramic heads, regardless of the extent of trunnion damage noted intraoperatively.
Collapse
Affiliation(s)
- Paul Dobria
- Chicago Medical School, Rosalind Franklin University of Medicine and Science, North Chicago, IL, USA
- Corresponding author. 3333 Green Bay Rd, North Chicago, IL 60064, USA. Tel.: +1 773 750 1369.
| | - Arpan Patel
- Department of Orthopedics, Rush University Medical Center, Chicago, IL, USA
| | - Brett Levine
- Department of Orthopedics, Rush University Medical Center, Chicago, IL, USA
| |
Collapse
|
5
|
Duensing IM, Stanley S, Bolognesi M. Fracture of a 40-mm BIOLOX Delta Femoral Head. Arthroplast Today 2021; 10:144-148. [PMID: 34401417 PMCID: PMC8353345 DOI: 10.1016/j.artd.2021.06.021] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Received: 03/29/2021] [Revised: 06/23/2021] [Accepted: 06/26/2021] [Indexed: 11/17/2022] Open
Abstract
Ceramic bearing surfaces have gained popularity in total hip arthroplasty as a result of the favorable mechanical properties and low wear rates. Despite the recognition as an attractive articulation, problems such as ceramic head fracture persist. Smaller heads and higher body mass indices are touted as risk factors for ceramic head fracture and are often associated with antecedent trauma. We present a case report of an 83-year-old male with a body mass index of 26.7 kg/m2 who suffered a fracture of a 40-mm ceramic femoral head. This occurred atraumatically 5 years from his index surgery. This patient underwent revision total hip arthroplasty which included debridement of ceramic debris and alteration of the bearing surface with femoral head and polyethylene liner exchange.
Collapse
Affiliation(s)
- Ian M Duensing
- Department of Orthopaedics, Duke University, Durham, NC, USA
| | - Samuel Stanley
- Department of Orthopaedics, Duke University, Durham, NC, USA
| | | |
Collapse
|
6
|
Incidence, Risk Factors, and Outcome of Ceramic-On-Ceramic Bearing Breakage in Total Hip Arthroplasty. J Arthroplasty 2021; 36:2992-2997. [PMID: 33812710 DOI: 10.1016/j.arth.2021.03.021] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Received: 01/23/2021] [Revised: 03/02/2021] [Accepted: 03/04/2021] [Indexed: 02/02/2023] Open
Abstract
BACKGROUND Ceramic-on-ceramic bearing breakage is a rare but significant complication of total hip arthroplasty. This study aimed to identify risk factors for breakage and to determine the outcome of different revision options. METHODS All ceramic-on-ceramic primary total hip arthroplasty procedures reported to the Australian Joint Replacement Registry from September 1999 to December 2019 were included. Procedures were subdivided into alumina or mixed ceramic (alumina/zirconia). All breakages were identified. The association between ceramic type and head size was assessed. Subsequent revision rates were compared and cause of revision assessed. RESULTS There were 23,534 alumina and 71,144 mixed ceramic procedures. Breakage was the reason for 1st revision in 84 alumina (5.27% of all revisions and 0.36% of procedures) and 56 mixed ceramic procedures (2.46% of all revisions; 0.08% of procedures). Alumina had a higher breakage rate than mixed ceramic (HR 2.50 (95% CI 1.75, 3.59), P < .001), and breakage was higher for 36-38mm head sizes using alumina (HR 2.84 (1.52, 5.31), P = .001). 17.8% of 2nd revisions occur by 3 years, due to dislocation, infection, metal-related pathology, and loosening. A neck adapter sleeve did not reduce 2nd revisions. Numbers were too low to compare revision bearing surface options. CONCLUSION Ceramic breakage has reduced with mixed ceramics but has a 0.79/1000 incidence at 15-year follow-up. It is unclear what the risk factors are for modern ceramics with increasing head size a risk for alumina only. Risk of 2nd revision is high and occurs early. The optimal revision option is unknown.
Collapse
|
7
|
Avila JD, Bandyopadhyay A. Zirconia-Toughened Alumina Coated Ti6Al4V via Additive Manufacturing. MATERIALS LETTERS 2021; 291:129577. [PMID: 33692601 PMCID: PMC7939135 DOI: 10.1016/j.matlet.2021.129577] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 05/14/2023]
Abstract
CoCr alloy-based femoral heads have failed prematurely due to galvanic-induced corrosion when coupled with a titanium hip stem. Coupling a titanium based-femoral head with the titanium hip stem is ideal in addressing this failure mode. Ti6Al4V (Ti64) alloy was reinforced with zirconia-toughened alumina (ZTA) by directed-energy deposition (DED)-based additive manufacturing (AM) to address that concern. Preliminary materials processing work resulted in failed samples due to cracking, porosity, and delamination. After careful parameter optimization, a Ti64+5wt.%ZTA (5ZTA) composition produced a metallurgically sound and coherent interface, minimal porosity, and bulk structures. Hardness was observed to increase by 27%, normalized wear rate reduced by 25%, and contact resistance increased during in vitro tribological testing along with faster surface re-passivation.
Collapse
|
8
|
Valentini R, Vacchiano A, Sandri A, Regis D, Dall'Oca C, Magnan B. Fourth generation head fracture in ceramic-on-polyethylene bearing after hip revision surgery: a case report. ACTA BIO-MEDICA : ATENEI PARMENSIS 2020; 91:248-253. [PMID: 32555105 PMCID: PMC7944813 DOI: 10.23750/abm.v91i4-s.9499] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/06/2020] [Indexed: 11/23/2022]
Abstract
Fourth generation ceramic bearings (BIOLOX delta, CeramTec AG; Phlochingen, Germany) were developed to reduce wear debris and improve fracture resistance. A case of a fourth generation head fracture in ceramic-on-polyethylene (COP) coupling after hip revision surgery is reported. A 58-year-old man was admitted to our department for increasing hip pain following a direct trauma which occurred during skiing activity 4 months before. Six years earlier, he had undergone a right cementless revision surgery with a 36-mm BIOLOX delta femoral head on polyethylene liner for metallosis and foreign body reaction after primary total hip replacement for hip osteoarthritis. At admission, radiological evaluation revealed a fracture of ceramic femoral head requiring a new revision surgery. Extensive synovectomy, lavage and capsulectomy were performed. Both acetabular cup and femoral stem were well fixed with no damage of trunnion, and therefore they were retained. A 36-mm internal diameter polyethylene acetabular liner was inserted along a 36-mm BIOLOX delta head with a BioBall adapter XL. The postoperative course was uncomplicated. At 1-year follow-up, the patient had a complete functional recovery. To our knowledge, BIOLOX delta ceramic femoral head fracture after COP hip revision surgery has not been previously reported.
Collapse
Affiliation(s)
- Roberto Valentini
- Department of Orthopaedic and Trauma Surgery, University of Verona, Italy, .
| | - Andrea Vacchiano
- Department of Orthopaedic and Trauma Surgery, University of Verona, Italy.
| | - Andrea Sandri
- Department of Orthopaedic and Trauma Surgery, University of Verona, Italy.
| | - Dario Regis
- Department of Orthopaedic and Trauma Surgery, University of Verona, Italy.
| | - Carlo Dall'Oca
- Department of Orthopaedic and Trauma Surgery, University of Verona, Italy.
| | - Bruno Magnan
- Department of Orthopaedic and Trauma Surgery, University of Verona, Italy.
| |
Collapse
|