Finite element simulation of early creep and wear in total hip arthroplasty

Polyethylene wear particulate has been implicated in osteolytic lesion development and may lead to implant loosening and revision surgery. Wear in total hip arthroplasty is frequently estimated from patient radiographs by measurement of penetration of the femoral head into the polyethylene liner. Penetration, however, is multi-factorial, and includes components of wear and deformation due to creep. From a clinical perspective, it is of great interest to separate these elements to better evaluate true wear rates in vivo. Thus, the aim of this study was to determine polyethylene creep and wear penetration and volumetric wear during simulated gait loading conditions for variables of head size, liner thickness, and head–liner clearance. A finite element model of hip replacement articulation was developed, and creep and wear simulation was performed to 1 million gait cycles. Creep of the liner occurred quickly and increased the predicted contact areas by up to 56%, subsequently reducing contact pressures by up to 41%. Greater creep penetration was found with smaller heads, thicker liners, and larger clearance. The least volumetric wear but the most linear penetration was found with the smallest head size. Although polyethylene thickness increases from 4 to 16 mm produced only slight increases in volumetric wear and modest effects on total penetration, the fraction of creep in total penetration varied with thickness from 10% to over 50%. With thicker liners and smaller heads, creep will comprise a significant fraction of early penetration. These results will aid an understanding of the complex interaction of creep and wear.     

Investigation of explanted hip and acetabulum hip prostheses]

Retrieved ceramic femoral heads and acetabular cups were investigated. On the basis of the case studies, the reasons for revision are discussed. Wear patterns and wear rates were found to differ from those observed in hip simulating testing. Monolithic ceramic cups showed a high wear rate. Owing to their limited range of motion, ceramic "mushroom heads" are associated with impingement that leads to a high risk of cup loosening, high wear rates and in vivo fractures. The combination of ceramic "mushroom heads" and cups is not recommended. An evaluation of complications shows that some can be explained by patient behaviour--e.g. Japanese sitting position, horse riding. Designers need to develop new concepts offering a larger range of motion, for example, with head diameters of 32 and 36 mm that reduce the risk of impingement, subluxation and dislocation, while increasing the range of motion. The potential of ceramic/ceramic coupling has been known since the 70s, and ceramic concepts for total hip replacement are currently experiencing a renaissance, although further developments are still possible.     

A comparative study of the characteristics of femoral hip prosthesis heads--study and results ceramic-coated hip joint heads of titanium]

Today, only hard/soft cup and femoral head combinations are employed for hip joint prostheses. Highly polished ceramic is a material with very good tribological properties for femoral heads, being highly resistant to mechanical wear and tear, and highly resistant to chemical reactions in the biological environment. The advantage of metal heads, in contrast, undoubtedly lies in their resistance to breakage and the ease with which their geometry can be modified with respect, for example, to antirotation angle and neck length. The ideal material for femoral heads is a combination of the two materials. The new multi-layer combination of titanium-niobium oxide/nitride ceramic coating applied to a prehardened titanium head combines the positive material properties in an ideal manner. Femoral heads made of CoCrMo, oxide-hardened titanium, aluminium oxide or multilayer titanium-niobium ceramic were compared by means of friction an wear and tear tests. The TiNb-ceramic-metal heads showed similar abrasion at the surface as the ceramic heads. At the high loads of more than 400 kp, which may also be reached under physiological conditions, the specially coated titanium-ceramic heads proved to be superior in terms of resistance to fracture and tribological properties.     

Ceramic cups for hip endoprostheses. 5: Consideration of designs]

Using the combination ceramic on ceramic for hip prostheses, the wear rate can be reduced to less than 1 micron per million cycles. More than 20 years of experience are now available for various concepts involving alumina ceramics in THR. In the early days, monolithic ceramic cups were employed. However, since alumina ceramic has an unsatisfactory potential for bone integration, soft tissue forms at the interface, with the result that the sockets migrate and penetrate. To improve bony integration, monoblock cups surfaced with ceramic beads were introduced. For the past 10 years, there has been a trend towards the use of modular acetabular components comprising a metal shell and a liner made of Biolox forte ceramic. Two concepts for the fixation of the ceramic liners are employed: locking of the ceramic in the metal shell (CeraLock) and the sandwich concept with a polyethylene layer interposed between liner and shell. The basic design and important aspects such as diameter, range of motion, and the possibility for revision, clinical experience, and trends are discussed.     

Effects of episodic subluxation events on third body ingress and embedment in the THA bearing surface

In total joint arthroplasty, third body particle access to the articulating surfaces results in accelerated wear. Hip joint subluxation is an under-recognized means by which third body particles could potentially enter the otherwise closely conforming articular bearing space. The present study was designed to test the hypothesis that, other factors being equal, even occasional events of femoral head subluxation greatly increase the number of third body particles that enter the bearing space and become embedded in the acetabular liner, as compared to level-walking cycles alone. Ten metal-on-polyethylene hip joint head-liner pairs were tested in a multi-axis joint motion simulator, with CoCrMo third body particles added to the synovial fluid analog. All component pairs were tested for 2h of level walking; half were also subjected to 20 intermittent subluxation events. The number and location of embedded particles on the acetabular liners were then determined. Subluxation dramatically increased the number of third body particles embedded in the acetabular liners, and it considerably increased the amount of scratch damage on the femoral heads. Since both third body particles and subluxation frequently occur in contemporary total hip arthroplasty, their potent synergy needs to be factored prominently into strategies to minimize wear.     

Ceramic cups for hip endoprostheses. 6: Cup design, inclination and antetorsion angle modify range of motion and impingement]

The present investigation focuses on total hip replacement using ceramic acetabular components. The relationship between the position of the cup and the range of motion (ROM) was investigated. A limited range of motion may cause impingement, which is defined as contact between the femoral neck and the rim of the acetabular cup. Impingement may result in wear, chipping, fracture or dislocation of the femoral head. Joint movements were simulated in a three-dimensional CAD program. The results obtained underscore the importance of correct positioning and design of the cup for achieving a ROM as close to the physiological situation as possible. With ceramic cups, the inclination angle should not be more than 45 degrees, and the antetorsion angle between 10 and 15 degrees. If the cup is too vertical, the risk of dislocation and fracture of the ceramic increases. If, on the other hand, the angle of inclination is too small, flexion and abduction will be greatly limited. The study shows that acetabular components with non-recessed ceramic inserts should not be used. Slight recession of the insert helps to avoid impingement. The ROM is reduced and the risk of impingement appreciably increased when mushroom-shaped femoral heads (XL heads) or ceramic inserts protected by a polyethylene ring are used.     

Influence of demographic, surgical and implant variables on wear rate and osteolysis in ABG I hip arthroplasty

Periprosthetic osteolysis is associated with accelerated wear rates. The goal of this study was to investigate the influence of demographic and technical variables on wear rates and size of osteolytic lesions. Eighty retrieved ABG I prostheses were analyzed according to prospectively established criteria. There were 22 men and 58 women with an average age of 52 years (34-65) at the time of revision. The average time from index surgery to revision was 67 months (26 to 106). Polyethylene wear measurements were performed using a Universal-type measuring microscope. The average linear wear and volumetric wear rate was 0.363 mm per year (0-0.939, SD 0.241) and 161 mm(3) per year (0-467, SD 118.2), respectively. The wear rates were significantly higher (a) in patients with primary osteoarthritis in comparison with postdysplastic hips, (b) in hips where zirconia prosthetic heads articulated against the polyethylene liner, and (c) in cups placed laterally to Kohler's line. Risk that linear wear rate could be more than 0.2 mm per year was three times higher in patients who were operated in 1997 and later (OR 3.0, 95 % CI 1.126-7.993, p = 0.03). A strong association was revealed between magnitude of wear and size of femoral osteolysis.     

Titanium serum levels may remain elevated despite hip revision surgery for wear-through of an acetabular component.

A 62-year-old female patient showed radiographic signs of severe linear wear of the acetabular component six years after cementless total hip arthroplasty. This suggested wear-through of the acetabular liner with secondary wear of the titanium shell. At revision surgery wear-through of both the inlay and the acetabular shell were confirmed. Despite meticulous debridement serum titanium levels remained elevated for more than 12 months. Wear-through of a polyethylene acetabular liner with secondary wear of the titanium shell can lead to increased titanium serum levels. Titanium serum levels can remain highly elevated despite revision surgery.     

Improvement of the reliability of ceramic hip joint implants

The aim of this article is to present the optimization of a proof test procedure of ceramic hip joint ball heads. The proof test rejects defective samples in the production line before being implanted into human body. Thereby on every ceramic ball head a static load is applied, which is somewhat higher than the maximum physiological load. The magnitude of the applied load should not damage the samples which are free of flaws in the high stress area. The configuration of the proof test influences the stress distribution in the ball head, which should be similar to the physiological case. To determine the stress distribution, a non-linear finite element (FE) analysis was performed and the results were validated by measurements. With an iterative approach based on FE calculations the proof test configuration was optimized in such a way that the stress distribution in the ball head is similar to the stress distribution in vivo. In this study all ball heads showed very high fatigue resistance after being proof tested and fulfilled the requirements of the FDA (Food and Drug Administration, USA) described in the Guidance Document for the Preparation of Premarket Notifications for Ceramic Ball Hip System. The probability of a fracture of an implanted ceramic ball head can be decreased by the presented optimized proof test procedure. Latter can thus improve the reliability of ceramic hip joint ball heads. The study was supported by the KTI (Commission for Technology and Innovation, Switzerland).     

Bone bank service in Odense, Denmark. Audit of the first ten years with bone banking at the Department of Orthopaedics, Odense University Hospital

There has been an increase in the demand for allograft bone in recentyears. The Odense University Hospital bone bank has been in function since1990,and this paper outlines our results during the 10 year period 1990–1999.Potential donors were screened by contemporary banking techniques which includea social history, donor serum tests for HIV, hepatitis B and C, and graftmicrobiology. The bones were stored at –80 °C. No typeofsecondary sterilisation was made. 423 femoral heads were approved and donatedto300 patients,1–6 heads/operation. The allografts have been used mainly toreconstruct defects at revision hip arthroplasty (34%), and for fracturesurgery(24%). 7 % of all transplanted patients were reoperated because of infection.Inthe hip revision group the infection rate was 4 %. There were no cases ofdisease transmission. During the 10 year period there was a change in theclinical use of the allografts. In the first years the allografts were mainlyused for spinal fusion surgery, but today the majority are used in hip revisionand fracture surgery. The clinical results correspond to those reported inlarger international series.     

The Morse taper junction in modular revision hip replacement--a biomechanical and retrieval analysis.

All biomaterials used for total joint surgery are subjected to wear mechanisms. Morse taper junctions of modular hip revision implants are predilection sites for both fretting and crevice corrosion, dissociation and breakage of the components. The aim of this study is to quantify wear and study metallurgical changes of Morse taper junctions of in-vitro and in-vivo loaded modular revision stems. Three modular revision stems (MRP-Titan, Peter Brehm GmbH, Germany) were loaded by a servohydraulic testing machine. The loads and conditions used exceeded by far the values required by ISO-standard 7206. The tests were performed with maximum axial loads of 3,500 N to 4,000 N over 10-12 x 10(6) cycles at 2 Hz. Additionally, the female part of the taper junctions were coated with blood and bone debris. The free length of the implant was set to 200 mm. One other MRP stem was investigated after retrieval following 5.5 years of in-vivo use. All contact surfaces of the modular elements were assessed by visual inspection, optical microscopy and scanning electron microscopy (SEM). The degree of plastic deformation of the male part of the morse taper junction was determined by contouroscopy. None of the morse taper junctions broke or failed mechanically. Corrosion and wear affected all tapers, especially at the medial side. The retrieved implant showed no cracks and the amount of debris measured only one third of that for the stems tested in-vitro. The present retrieval and laboratory investigations have proven, that the morse taper junctions of the MRP-titanium stem are stable and resistant to relevant wear mechanisms. The longevity of the junctions for clinical use is given. If an optimal taper design is selected, the advantages of modular femoral components in total hip revision arthroplasty will outweigh the possible risks.     

Fracture analysis of a ceramic liner. Is in hip endoprosthesis replacement of ceramic on ceramic components with only one of the corresponding partners justified?]

The good biomechanical and tribological properties, together with the excellent biocompatibility, of ceramic-on-ceramic components, make them a preferential choice for total hip replacement surgery, at least in Europe. We report on a man admitted as an outpatient with painless grating in the hip one year after replacement of a ceramic femoral head, but not of the ceramic inlay. Clinical and radiological findings were indicative of a broken liner. This was confirmed during revision surgery, during which it was replaced by a polyethylene inlay; although the ceramic head appeared intact, it was replaced by a metal head. Inspection of the surface of the broken liner in the scanning electron microscope (SEM) revealed signs of material failure. We recommend careful inspection of ceramic-on-ceramic articulating components during total hip revision surgery and if there is any uncertainty, replacement of both so as to avoid premature failure.     

Effects of clinically relevant alumina ceramic, zirconia ceramic and titanium particles of different sizes and concentrations on TNF-alpha release in a human macrophage cell line]

INTRODUCTION: Aseptic loosening is considered to be the main problem of modern endoprothesis. Tumor necrosis factor alpha (TNFalpha) seems to be the initiator protein of particle disease. The aim of our study was to investigate the TNFalpha response of macrophage like cells (MLC) after stimulation with periprosthetic particles, typically found during revision surgery. For this purpose alumina ceramic (Al2O3), zirconia ceramic (ZrO2) and titanium (Ti) particles of different sizes and concentrations were used. Important was to study the effects of different sizes due to TNFalpha secretion and the comparison of the biological effects of alumina ceramic and titanium. METHOD: To obtain an TNFalpha profile we used an established macrophage model (Rader et al.) with THP-1 cells (human monocytic cell line). Therefore 106 MLC were incubated with different particle concentrations and sizes for 6 h. The supernatant was then investigated for TNF using ELISA assay. RESULTS: Ti-particles provoked in both sizes (0.2 microm and 2.5 microm) the greatest TNFalpha response, 8 times and 17 times as high in comparison with control. But substantially more 0.2 microm sized Ti-particles were necessary to get the above mentioned results. Al2O3-particles were not as effective as Ti, but they released fourfold more TNFalpha compared to control. There was no difference in TNFalpha-secretion comparing Al2O3-particles of different sizes (0.6 microm and 2 microm), but a 1000 times greater concentration of the 0.6 microm sized particles were needed. Using Al2O3- and Ti-particles of the same size and concentration, Ti provoked a significant higher TNFalpha response. ZrO2 showed no effects on TNFalpha release. CONCLUSION: Because of our results we recommend ceramic articulating surfaces, which are superior to metal on metal matings ion term of biological reactions. Additionally bigger wear particles should be avoided. Revisionoperation should be done early to avoid huge amount of wear particles and to minimize local osteolysis.     

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.     

Wear Performance of Ceramic-On-Metal Hip Bearings

Ceramic-on-metal (CoM) bearings are considered to be a promising alternative to polyethylene-based bearings or hard-on-hard bearings (Ceramic-on-Ceramic (CoC) and Metal-on-Metal (MoM)). Although, CoM shows lower wear rates than MoM, in-vitro wear testing of CoM shows widely varying results. This may be related to limitations of wear-measuring methods. Therefore, the aim of this study was to improve the gravimetric measurement technique and to test wear behaviour of CoM bearings compared to CoC bearings. Level walking according to ISO-14242 was simulated for four CoM and four CoC bearings. Prior to simulation, errors in measurement of gravimetric wear were detected and improvements in measurement technique incorporated. The results showed no differences in mean wear rates between CoM and CoC bearings. However, the CoM bearings showed wear results over a wide range of wear performance. High reliability of wear results was recorded for the CoC bearings. Material transfer was observed on the ceramic heads of the CoM bearings. Therefore, for level walking a partial mixed or boundary lubrication has to be assumed for this type of bearing. CoM is a highly sensitive wear-couple. The reasons for the observed behaviour cannot be clarified from this study. Simulator studies have to be considered as an ideal loading condition. Therefore, high variations in wear rates as seen in this study, even at low levels, may have an adverse effect on the in-vivo wear behavior. Careful clinical use may be advisable until the reasons for the variation are fully clarified and understood.     

Relevance of the insertion force for the taper lock reliability of a hip stem and a ceramic femoral head]

In endoprosthetics alumina ceramic femoral heads have been established for many years and their outstanding wear characteristics are scientifically proven. The taper connection between the hard but brittle ceramic head and the metallic stem must be performed by the operating surgeon intraoperatively. Thereby it is left to the surgeon to interpret imprecise and strongly deviating instructions given from manufacturer to manufacturer. This study clarifies the enormously large variations of interpretation in the clinical everyday life based on interviews and force measurements during handling when assembling. In comparable situations the axial cone setting forces, applied by a total of 39 operating surgeons from German hospitals, varied between 273 N and 7848 N. An additional coupling strength examination in the laboratory shows that torque loadings necessary for loosening several cone connection designs are in the range of those occurring under usual in vivo situations. This leads to the conclusion that for low-force-connected cone tapers joint friction of the artificial hip joint can cause a rotation and thus a loosening of the ceramic head of the implant neck during everyday activities. The authors proclaim the urgent necessity for clear handling references and the supply of a reproducibly safe taper lock method.     

New compounds for improving wear behavior of a tumor knee endoprosthesis]

Wear of the central bushing made of ultra-high molecular weight polyethylene (PE-UHMW) of the hinged knee endoprosthesis of a tumour-resection system is the leading reason for revision. The aim of the study was to optimize the wear characteristics of the endoprosthesis on the basis of the tribological properties of new materials and an additional finite element (FE) calculation taking account of the given design. In screening tests the reference combination of PE-UHMW bushing and CoCr axis--used in the clinical setting--was first tested. The PE-UHMW bushing was then replaced by one made of each of the materials reinforced high-density polyethylene (PE-HD) and carbon fibre-reinforced epoxy resin (CFRP). In addition, a new material combination with an alumina ceramic bushing and a CFRP axis was investigated. In comparison with the reference combination PE-UHMW/metal, the combination of ceramic bushing and CFRP axis showed less wear. However, with the particular design of the prosthesis studied here, high mechanical loading applied experimentally resulted in mechanical failure. FE calculations confirmed these experimental results. Improvement of the wear characteristics of this specific implant caused therefore be achieved only by optimizing the bearing design.     

Does a micro-grooved trunnion stem surface finish improve fixation and reduce fretting wear at the taper junction of total hip replacements? A finite element evaluation

The generation of particulate debris at the taper junction of total hip replacements (THRs), can cause failure of the artificial hip. The taper surfaces of femoral heads and trunnions of femoral stems are generally machined to a certain roughness to enhance fixation. However, the effect of the surface roughness of these surfaces on the fixation, wear and consequently clinical outcomes of the design is largely unknown. In this study, we asked whether a micro-grooved trunnion surface finish (1) improves the fixation and (2) reduces the wear rate at the taper junction of THRs. We used 3D finite element (FE) models of THRs to, firstly, investigate the effect of initial fixation of a Cobalt-Chromium femoral head with a smooth taper surface mated with a Titanium (1) micro-grooved and (2) smooth, trunnion surface finishes. Secondly, we used a computational FE wear model to compare the wear evolution between the models, which was then validated against wear measurements of the taper surface of explanted femoral heads. The fixation at the taper junction was found to be better for the smooth couplings. Over a 7 million load cycle analysis in-silico, the linear wear depth and the total material loss was around 3.2 and 1.4 times higher for the femoral heads mated with micro-grooved trunnions. It was therefore concluded that smooth taper and trunnion surfaces will provide better fixation at the taper junction and reduce the volumetric wear rates.     

Slide track analysis of eight contemporary hip simulator designs

In an earlier paper, the authors presented a new method of computation of slide tracks in the relative motion between femoral head and acetabular cup of total hip prostheses. For the first time, computed tracks were verified experimentally and with an alternative method of computation. Besides being an efficient way to illustrate hip kinematics, the shapes of the slide tracks are known to be of fundamental importance regarding the wear behaviour of prostheses. The verified method was now applied to eight contemporary hip simulator designs. The use of correct motion waveforms and an Euler sequence of rotations in each case was again found to be essential. Considerable differences were found between the simulators. For instance, the shapes of the tracks drawn by the resultant contact force included a circle, ellipse, irregular oval, leaf, twig, and straight line. Computation of tracks correctly for the most widely used hip simulator, known as biaxial, was made possible by the insight that the device is actually three-axial. Slide track patterns have now been computed for virtually all contemporary hip simulators, and both for the heads and for the cups. This comparative analysis forms a valuable basis for studies on the relationship between the type of multidirectional motion and wear. These studies can produce useful information for the design of joint simulators, and improve the understanding of wear phenomena in prosthetic joints.     

Study on Biotribological Behavior of the Combined Joint of CoCrMo and UHMWPE/BHA Composite in a Hip Joint Simulator

UHMWPE composites reinforced with Bovine Bone Hydroxyapatite(BHA)in different contents were prepared by heatpressing formation method.A hip joint wear simulator was used to investigate the biotribological behavior of UHMWPE/BHAcomposite acetabular cups against CoCrMo alloy femoral heads in bovine synovia lubrication at 37±1 ℃.It was found that theaddition of BHA powder to UHMWPE can improve the hardness and creep modulus of UHMWPE/BHA composites,anddecrease their wear rates under bovine synovia lubrication.When the content of BHA filler particles was up to 30 wt%,UHMWPE/BHA composites demonstrated the well design performances of the surface and biotribological properties.Fatigue,ploughing and slight adhesive wear were the main wear mechanisms for UHMWPE and its composites.In addition,the sizes ofwear particles became larger with an increase in BHA powder addition.These results suggest that BHA filler is a desirablecomponent to increase the wear resistance of UHMWPE/BHA composites for biomedical applications.