Graham Isaac

Tribology and wear of metal-on-metal hip prostheses: influence of cup angle and head position.

BACKGROUND Clinical studies have indicated that the angular position of the acetabular cup may influence wear in metal-on-metal total hip bearings. A high cup angle in comparison to the anatomical position may lead to the head being constrained by the superior lateral surface and rim of the cup, thus potentially changing the location of the contact zone between the head and the cup. The aim of this study was to test the hypothesis that both a steep cup angle and a lateralized position of the head can increase head contact on the superior rim of the cup, with the consequence of increased wear. METHODS Hip-joint simulator studies of metal-on-metal bearings were undertaken with cup angles of 45 degrees and 55 degrees . The femoral head was either aligned to the center of the cup or placed in a position of microlateralization. Wear was measured gravimetrically over 5 million cycles. RESULTS A steep cup angle of 55 degrees showed significantly higher long-term steady-state wear than a standard cup angle of 45 degrees (p < 0.01). The difference was fivefold. Microlateralization of the head resulted in a fivefold increase in steady-state wear compared with a centralized head. The combination of a steep cup angle and a microlateralized head increased the steady-state wear rate by tenfold compared with a standard cup angle with a centralized head. CONCLUSIONS These studies support the hypothesis that both an increased cup angle and a lateral head position increase wear in metal-on-metal hip prostheses.

The Influence of Scratches to Metallic Counterfaces on the Wear of Ultra-High Molecular Weight Polyethylene

A number of studies of explanted metallic femoral heads have shown scratches or damage caused by bone cement, bone or metallic particles. This damage has been cited as a cause of increased wear of ultra-high molecular weight polyethylene (UHMWPE) acetabular cups. In this laboratory study, small scratches 2 μm deep were made on smooth stainless steel surfaces at a spacing of 10 mm. These individual scratches were found to increase the wear rate of UHMWPE by a factor of 30 in unidirectional sliding and a factor of 70 in reciprocating motion. It is of particular concern that a single small scratch, which is not detected by the average surface roughness measurement Ra can cause such a dramatic increase in the wear of ultra-high molecular weight polyethylene.

A tribological study of retrieved hip prostheses.

One hundred Charnley cemented acetabular cups, 78 of which had the associated femoral stems, were obtained after revision surgery. Patient characteristics, which were obtained from hospital records, and roentgenographs showed that component loosening was the most common cause of failure. Examination of the acetabular cups revealed six categories of damage: socket erosion, rim wear, cement ingress, cratering, discoloration, and articulating surface scoring. Damage to the femoral stems was characterized by stem fracture and roughening of the femoral head. The latter was predominantly caused by the roentgenographic contrast medium within the acrylic cement scratching the articulating surface. The amount of wear, in terms of the penetration of the femoral head into the acetabular cup, could be measured in 87 cases. The mean penetration was 1.69 mm and the mean penetration rate was 0.21 mm per year with a range from less than 0.005 mm to 0.6 mm per year. It was shown that within this group, a high penetration rate precludes a long service life. It is therefore likely that reducing the rate of wear would improve the performance of the artificial hip joint.

Effect of bearing size on the long‐term wear, wear debris, and ion levels of large diameter metal‐on‐metal hip replacements—An in vitro study

Hip resurfacing arthroplasty has become a popular alternative to conventional hip surgery. Surface replacements with bearing sizes of 55 mm (n = 5) and 39 mm (n = 5) were tested in a hip simulator for 15 million cycles (Mc). Wear debris was isolated from the serum lubricant and characterized by field emmitting gun scanning electorn microscopy, and ion levels were measured via inductively coupled plasma mass spectroscopy at intervals throughout the test. The 39 mm bearings showed significantly greater bedding in volumetric wear (2.58 mm(3)) compared with the 55 mm bearings (1.15 mm(3)). There was no significant difference between the steady state wear rates (1-15 Mc) between the two sizes (0.10 and 0.09 mm(3)/Mc, respectively); however, this parity only became clear after 7 Mc. The wear debris isolated was oval in morphology with a mean particle size of 28 nm and a range of 9-108 nm. The Co levels measured at 0.13 Mc were significantly greater than at 3.6 Mc for both bearing sizes (10926 ppb and 176 ppb, respectively). After 0.5 Mc, the Co levels from the 39 mm bearings were significantly higher than the 55 mm (11,007 vs. 1475 ppb). The wear results support previous findings showing that increasing the femoral head size decreased volumetric bedding in wear. The ion levels measured suggest both bearing sizes have similar initial wear rates; however, the 55 mm bearings reach steady state wear more rapidly.

An in vitro study of the reduction in wear of metal-on-metal hip prostheses using surface-engineered femoral heads

Abstract Although the wear of existing metal-on-metal (MOM) hip prostheses (1 mm3/106 cycles) is much lower than the more widely used polyethylene-on-metal bearings, there are concerns about the toxicity of metal wear particles and elevated metal ion levels, both locally and systemically, in the human body. The aim of this study was to investigate the possibility of reducing the volume of wear, the concentration of metal debris and the level of metal ion release through using surfaceengineered femoral heads. Three thick (8-12 μm) coatings (TiN, CrN and CrCN) and one thin (2 μm) coating (diamond-like carbon, DLC), were evaluated on the femoral heads when articulating against high carbon content cobalt-chromium alloy acetabular inserts (HC CoCrMo) and compared with a clinically used MOM cobalt-chromium alloy bearing couple using a physiological anatomical hip joint simulator (Leeds Mark II). This study showed that CrN, CrCN and DLC coatings produced substantially lower wear volumes for both the coated femoral heads and the HC CoCrMo inserts. The TiN coating itself had little wear, but it caused relatively high wear of the HC CoCrMo inserts compared with the other coatings. The majority of the wear debris for all half-coated couples comprised small, 30 nm or less, CoCrMo metal particles. The Co, Cr and Mo ion concentrations released from the bearing couples of CrN-, CrCN- and DLC-coated heads articulating against HC CoCrMo inserts were at least 7 times lower than those released from the clinical MOM prostheses. These surface-engineered femoral heads articulating on HC CoCrMo acetabular inserts produced significantly lower wear volumes and rates, and hence lower volumetric concentrations of wear particles, compared with the clinical MOM prosthesis. The substantially lower ion concentration released by these surface-engineered components provides important evidence to support the clinical application of this technology.

Deformation of press-fitted metallic resurfacing cups. Part 1: Experimental simulation:

Abstract The interference press fit of a metallic one-piece acetabular cup employed for metal-on-metal hip resurfacing procedures was investigated experimentally under laboratory conditions in the present study, in particular regarding the cup deformation. Tests were carried out in cadavers as well as polyurethane foams of various grades with different elastic moduli to represent different cancellous bone qualities. The cadaver test was used to establish the most suitable configuration of the foam model representing realistic support and geometrical conditions at the pelvis. It was found that a spherical cavity, with two identical areas relieved on opposite sides, was capable of creating a two-point pinching action of the ischeal and ilial columns on the cup as the worst-case scenario. Furthermore, the cup deformation produced from such a two-point loading model with a grade 30 foam was similar to that measured from the cadaver test. Therefore, such a protocol was employed in subsequent experimental tests. For a given size of the outside diameter of the cup of 60 mm, the cup deflection was shown to be dependent largely on the cup wall thickness and the diametral interference between cup and prepared cavity at implantation. For a relatively thin cup with a wall thickness between 2.3 mm (equator) and 4 mm (pole) and with a modest nominal diametral interference of 1 mm, which corresponds to an actual interference of approximately 0.5 mm, the maximum diametral cup deflection (at the rim) was around 60 μm, compared with a diametral clearance of 80-120 μm between the femoral head and the acetabular cup, generally required for fluid-film lubrication and tribological performances. Stiffening of the cup, by both thickening and lateralizing by 1 mm, reduced the cup deformation to between 30 and 50 μm with actual diametral interferences between 0.5 and 1 mm.

The 2007 Otto Aufranc Award. Ceramic-on-metal hip arthroplasties: a comparative in vitro and in vivo study.

The performance of novel ceramic-on-metal bearing couples has been compared with metal-on-metal and ceramic-on-ceramic bearing couples in laboratory and short-term clinical studies. Laboratory studies compared ceramic-on-metal with metal-on-metal and ceramic-on-ceramic bearings with diameters of 28 and 36 mm under standard conditions and under adverse conditions with head loading on the rim of the cup. Clinical studies compared metal ion levels in ceramic-on-metal with metal-on-metal, ceramic-on-ceramic, and ceramic-on-polyethylene bearings in a randomized prospective study. In the laboratory studies, friction, wear, and ion levels were lower in ceramic-on-metal bearings compared with metal-on-metal, with results similar to ceramic-on-ceramic couples. Under adverse conditions and rim loading, all bearings showed increased wear with lower wear and absence of stripe wear in ceramic-on-metal compared with metal-on-metal bearings. Short-term studies in 31 patients at 6 months revealed lower metal ion levels (cobalt and chromium) in those with ceramic-on-metal compared with metal-on-metal bearings.Level of Evidence: Level II, therapeutic study. See the Guidelines for Authors for a complete description of levels of evidence.

Metal-on-metal bearings surfaces: materials, manufacture, design, optimization, and alternatives.

Abstract When first introduced, total hip replacements offered pain relief and improved mobility in elderly patients. The success of this procedure in terms of long-term durability and restoration of function has led to its use in younger, more active patients. This has resulted in a commensurate increase in patient expectation regarding longevity and the degree to which function and lifestyle is restored. The bearing surface is a key feature of the performance of replacement joints. It is generally accepted that excessive amounts of wear debris preclude their long-term survivorship and hence there is an ongoing requirement for bearing surfaces which minimize debris generation. The purpose of this paper is to review the factors which affect the performance of so-called metal-on-metal bearings, to compare their performance with that of the other commonly used contemporary alternatives, metal and ceramic articulating against highly cross-linked polyethylene, and ceramic-on-ceramic, and finally to consider the potential solutions offered by new developments such as ceramic-on-metal and coatings applied to metal-on-metal bearings.

Laboratory wear tests and clinical observations of the penetration of femoral heads into acetabular cups in total replacement hip joints. II: A microscopical study of the surfaces of Charnley polyethylene acetabular sockets

Abstract In this paper attention is focused on the findings of a recent microscopical study of explanted polyethylene hip joints from Wrightington Hospital. The project was initiated some years ago in collaboration with the late Professor Sir John Charnley, but the present study is based on an extended study of acetabular cups which have been sectioned for direct examination in the electron microscope for the first time. The account of the appearance of worn polyethylene acetabular cups reported in this paper provides a useful basis for the quantitative assessment of wear in the current form of Charnley low friction arthroplasties reported in part III of the present trio of papers. It has been confirmed that worn polyethylene acetabular sockets exhibit three distinct regions: a relatively smooth high wear region in the superior half of the cup, a rougher low wear area in which the original machining marks are still visible and a low ridge separating the two. Rim wear associated with impingement of the femoral stem is also evident in some of the heavily worn sockets. Some five cups representing service lives ranging from 1 to 14 years were selected for detailed visual examination. Descriptions of the high and low wear regions are offered and it will be evident from the geometry of the intermediate ridge region that creep cannot have contributed significantly to the overall penetration of the femoral head into the acetabular cup. This point is discussed further in part III. Perhaps the most significant finding is that cement was found in all the cups examined. The adhesive wear process evident in the high wear region was supplemented by scratching or abrasive wear associated with cement ingress. It was concluded that cement in the explanted polyethylene cups of total replacement hip joints contributed to the appearance of the worn regions and, no doubt, to the wear process itself. It is expected that new designs of acetabular cups and improved surgical techniques will be of considerable benefit in this context.

Ceramic-on-metal bearings in total hip replacement: whole blood metal ion levels and analysis of retrieved components.

This study reports on ceramic-on-metal (CoM) bearings in total hip replacement. Whole blood metal ion levels were measured. The median increase in chromium and cobalt at 12 months was 0.08 microg/1 and 0.22 microg/1, respectively, in CoM bearings. Comparable values for metal-on-metal (MoM) were 0.48 microg/1 and 0.32 microg/1. The chromium levels were significantly lower in CoM than in MoM bearings (p = 0.02). The cobalt levels were lower, but the difference was not significant. Examination of two explanted ceramic heads revealed areas of thin metal transfer. CoM bearings (one explanted head and acetabular component, one explanted head and new acetabular component, and three new heads and acetabular components) were tested in a hip joint simulator. The explanted head and acetabular component had higher bedding-in. However, after one million cycles all the wear rates were the same and an order of magnitude less than that reported for MoM bearings. There were four outliers in each clinical group, primarily related to component malposition.