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.     

Microstructure analysis and wear behavior of titanium cermet femoral head with hard TiC layer

Titanium cermet was successfully synthesized and formed a thin gradient titanium carbide coating on the surface of Ti6Al4V alloy by using a novel sequential carburization under high temperature, while the titanium cermet femoral head was produced. The titanium cermet phase and surface topography were characterized with X-ray diffraction (XRD) and backscattered electron imaging (BSE). And then the wear behavior of titanium cermet femoral head was investigated by using CUMT II artificial joint hip simulator. The surface characterization indicates that carbon effectively diffused into the titanium alloys and formed a hard TiC layer on the Ti6Al4V alloys surface with a micro-porous structure. The artificial hip joint experimental results show that titanium cermet femoral head could not only improve the wear resistance of artificial femoral head, but also decrease the wear of UHMWPE joint cup. In addition, the carburized titanium alloy femoral head could effectively control the UHMWPE debris distribution, and increase the size of UHMWPE debris. All of the results suggest that titanium cermet is a prospective femoral head material in artificial joint.     

Ceramic acetabulum for hip endoprostheses. 8: Revisions]

For total hip replacement, ceramic femoral heads and acetabular liners are being used with success. However, reports of revision surgery necessitated by fractures or marked wear of ceramic components are still being published. The revision rate due to fracture is less than 0.01%, and much lower than for other complications. Nevertheless, improvement of safety remains a topic of discussion. This article reviews the results of investigations of explanted ceramic heads and liners, and discusses the problems caused by ceramic wear and chipping. Recommendations for revision surgery in such cases are given.     

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.     

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.     

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.     

Prediction of lubricating film thickness in UHMWPE hip joint replacements

An elastohydrodynamic lubrication model developed for a ball-in-socket configuration in a previous studies by the present authors (Jalali-Vahid et al., Thinning films and tribological interfaces, 26th Leeds-Lyon Symposium on Tribology, 2000, pp. 329-339) was applied to analyse the lubrication problem of a typical artificial hip joint replacement, consisting of an ultra-high molecular weight polyethylene (UHMWPE) acetabular cup against a metallic or ceramic femoral head. The cup was assumed to be stationary whilst the ball was assumed to rotate at a steady angular velocity and under a constant load. A wide range of main design parameters were considered. It has been found that the predicted lubricating film thickness increases with a decrease in the radial clearance, an increase in the femoral head radius, an increase in UHMWPE thickness and a decrease in UHMWPE modulus. However, the predicted lubricating film thicknesses are not found to be sufficiently large in relation to the surface roughness of the cup and head to indicate separation of the two articulating surfaces. It should also be noted that if the design features are unable to secure full fluid film lubrication, it may be preferable to select them for minimum wear rather than maximum film thickness. For example, an increase in head radius will enhance the film thickness, but it will also increase the sliding distance and hence wear in mixed or boundary lubrication conditions. Furthermore, it is pointed out that an increase in the predicted lubricant film thickness is usually associated with an increase in the contact area, and this may cause lubricant starvation and stress concentration at the edge of the cup, and adversely affect the tribological performance of the implant. The effect of running-in process on the lubrication in UHMWPE hip joint replacements is also discussed.     

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.     

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.     

RSA wear measurements with or without markers in total hip arthroplasty

Novel algorithms for radiostereometric (RSA) measurements of the femoral head and metal-backed, hemi-spherical cups of a total hip replacement are presented and evaluated on phantom images and clinical double examinations of 20 patients. The materials were analysed with classical RSA and three novel algorithms: (1) a dual-projection head algorithm using the outline of the femoral head together with markers in the cup; (2) a marker-less algorithm based on measurements of the outline of the femoral head, the cup shell and opening circle of the cup; and (3) a combination of both methods. The novel algorithms improve current, marker-based, RSA measurements, as well as allows studies without marked cups. This opens the possibility of performing wear measurements on larger group of patients, in clinical follow-ups, even retrospective studies. The novel algorithms may help to save patient data in current RSA studies lost due to insufficiently marked cups. Finally, the novel algorithms simplify the RSA procedure and allow new studies without markers, saving time, money, and reducing safety concerns. Other potential uses include migration measurements of re-surfacing heads and measuring spherical sections as implant landmarks instead of markers.     

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).     

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.     

Ceramic acetabular cups for hip endoprostheses. 7: How do position of the center of rotation and the CCD angle of the shaft modify range of motion and impingement?]

The range of motion (ROM) of total hip prostheses is influenced by a number of parameters. An insufficient ROM may cause impingement, which may result in subluxation, dislocation or material failure of the prostheses. In a three-dimensional CAD simulation, the position of the centre of rotation and the CCD angle of the stem were investigated. Displacement of the centre of rotation of the femoral head may be due to wear (PE cups) or to the design of the prosthesis (ceramic cups). Stems of widely differing design have been developed and implanted. The results of the present study demonstrate that the ROM is clearly reduced by increasing penetration of the femoral head. At an inclination angle of 45 degrees, a depth of penetration of 2 mm restricts flexion by about 15 degrees, and a depth of penetration of 3 mm by about 30 degrees. At smaller angles of inclination the ROM is reduced and flexion and abduction are associated with an increased risk of impingement. With steeper acetabular cup inclinations, the risk of impingement decreases, but dislocation, the risk of rim fractures (ceramic cups), and wear and penetration rates (PE cups) increase. The CCD angle of the stem should be oriented to the anatomical situation. At high CCD angles (> 135 degrees), flexion is clearly limited, in particular when there is penetration of the femoral head. For modern total hip arthroplasty, prosthetic systems characterised by precise positioning of components, minimum wear, slightly recessed inserts, and appropriate CCD angles should be used.     

Design considerations for ceramic resurfaced femoral head: effect of interface characteristics on failure mechanisms

Ceramic hip resurfacing may offer improved wear resistance compared to metallic components. The study is aimed at investigating the effects of stiffer ceramic components on the stress/strain-related failure mechanisms in the resurfaced femur, using three-dimensional finite element models of intact and resurfaced femurs with varying stem–bone interface conditions. Tensile stresses in the cement varied between 1 and 5 MPa. Postoperatively, 20–85% strain shielding was observed inside the resurfaced head. The variability in stem–bone interface condition strongly influenced the stresses and strains generated within the resurfaced femoral head. For full stem–bone contact, high tensile (151–158 MPa) stresses were generated at the cup–stem junction, indicating risk of fracture. Moreover, there was risk of femoral neck fracture due to elevated bone strains (0.60–0.80% strain) in the proximal femoral neck region. Stresses in the ceramic component are reduced if a frictionless gap condition exists at the stem–bone interface. High stresses, coupled with increased strain shielding in the ceramic resurfaced femur, appear to be major concerns regarding its use as an alternative material.     

A new ISO/FDIS 14242-1 compatible hip prosthesis simulator: E-SIM]

The continuing development of new, highly sophisticated materials for the articulating surfaces of total hip endoprostheses involves the need for testing, not only of biocompatibility and dynamic loadability, but also of tribological properties (friction, wear, lubrication). For decades, the wear resistance of these materials has been tested in wear simulators. In consequence of the currently often widely differing test methods, the technical committee (TC 150) of the ISO (International Organization for Standardization) has been concerned to develop an International Standard (ISO/FDIS 14242 1 and 2: Implants for Surgery--wear of total hip joint prostheses--on the basis of kinetic and kinematic data from gait analysis. This new standard will be the basis for ensuring the comparability of scientific data obtained from tribological testing of total hip endoprothesis. The new hip simulator, E-SIM, presented in this paper, complies with the currently published FDIS (Final Draft International Standard), and enables testing in accordance with these specifications.     

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.     

Mixing and matching in ceramic-on-metal hip arthroplasty: An in-vitro hip simulator study

The clinical success of second-generation metal-on-metal hip replacement and the good tribological performance of alumina ceramic revived an interest in hip articulation as a solution to reduce wear.This study was aimed at characterizing the wear behaviour of new hybrid ceramic-on-metal bearings. In particular, this study investigated the wear behaviour of ceramic-on-metal hip components (three different diameters configurations: 28, 32 and 36 mm), not specifically proposed to be coupled, in order to compare them with ceramic-on-ceramic, which is considered to be the gold standard for wear resistance. For this purpose, the weight loss over a standard wear simulation was monitored. Moreover, scanning electronic microscope observations were used to verify if any carbides removal, for the metallic components, triggered wears debris production promoting abrasive third-body wear.After five million cycles, our results showed significantly greater wear-in ceramic-on-metal compared with ceramic-on-ceramic, and significant greater wear for the 32-mm diameter compared with the 36-mm one. Our findings showed an increase in wear for the proposed hybrid specimens with respect to that of the ceramic-on-ceramic ones confirming that even in the case of ceramic-on-metal bearings, mixing and matching could not prove effective wear behaviour, not even comparable with that of the ceramic-on-ceramic gold standard. Wear patterns and roundness tolerances certainly discourage the coupling of components not specifically intended to be coupled. Unsuitable geometrical conformity could, in fact, result in a poor dynamic behaviour and lead to clinical failure.     

Finite element analysis of a cemented ceramic femoral component for the assembly situation in total knee arthroplasty]

The femoral components of the total knee replacements are generally made of metal. In contrast, ceramic femoral components promise improved tribological and allergological properties. However, ceramic components present a risk of failure as a result of stress peaks. Stress peaks can be minimised through adequate implant design, proper material composition and optimum force transmission between bone and implant. Thus, the quality of the implant fixation is a crucial factor. The objective of the present study was to analyse the influence of the cement layer thickness on stress states in the ceramic femoral component and in the femur. Two- and three- dimensional finite element analyses of an artificial knee joint with cement layers of different thickness and with an unbalanced cement layer thickness between the ceramic femoral component and the femur were performed. Higher stress regions occurred in the area of force transmission and in the median plane. The maximum calculated stresses were below the accepted tensile strength. Stresses were found to be lower for cement layer thickness of <2.0 mm.     

FE-analysis of surface stresses for the tribological system in total hip prostheses]

The implantation of a total hip prosthesis is an operation which is performed frequently due to advanced hip joint damage both in humans and in veterinary medicine in dogs. The long-term result of a hip prosthesis is mainly determined by aseptic loosening of the prosthesis; among other causes, abrasion particles of the tribological pairing are responsible for the loosening. For the analysis of the surface stresses with different tribological pairings, a finite element model was generated which was based on the CAD data of a commercial total hip prosthesis. After transmission of a physiological force in the components of the three tribological pairings ceramic/polyethylene, ceramic/ceramic and metal/polyethylene, stresses were calculated. Stresses in the ceramic/ceramic tribological pairings were conspicuously higher than in the other material pairings. In the future adapted prostheses have to be developed that ensure optimal friction and absorption characteristics of the components.     

Total hip arthroplasty wear simulation using the boundary element method

In this paper an application of the boundary element method for simulating wear in total hip prosthesis is presented. Several examples including different update periods of the worn acetabular cup, various femoral head sizes and various materials for both the femoral head and the acetabular cup are simulated under the same variable loading conditions for up to 20 years of service. Moreover, two different femoral models are considered in order to investigate the influence of the femoral modelling. The analysis demonstrates that due to the boundary only modelling requirement, the computational time and storage remains low, allowing large service periods to be simulated. Generally, the results obtained are in good agreement with other researchers findings. Moreover, ignoring the bending of the femoral neck in the model, results in a small overestimation of the maximum wear depth, while the volumetric wear is slightly underestimated. However, these differences are trivial considering the reduction of the computational effort.