John M. Cuckler

Early Failure of a Cross-Linked Polyethylene Acetabular Liner: A Case Report

The use of highly cross-linked ultra-high molecular weight polyethylene in total hip arthroplasty has become a popular alternative to the use of conventional polyethylene. Evaluations with use of hip simulator tests1-4 and clinical evaluations of total hip replacements5-10 have independently shown that polyethylene materials processed with gamma irradiation followed by melting or annealing have extremely low wear rates. However, it also has been demonstrated that such cross-linking processes may reduce the fracture toughness and resistance to fatigue crack propagation of polyethylene11-16. Bradford et al.14 found that retrieved cross-linked polyethylene acetabular liners exhibited surface cracking that had not been predicted by in vitro hip simulator studies. Tower et al.17 observed fatigue failure at the superior aspect of the rim of four retrieved highly cross-linked acetabular bearings. They concluded that the factors contributing to these failures included thin polyethylene at the cup rim, a relatively vertical cup alignment, and compromised material properties of the cross-linked polyethylene in comparison with conventional polyethylene. In the current case report, we describe the failure of a highly cross-linked polyethylene acetabular liner less than three years after implantation. We believe that the mechanisms of failure were fracture of the cross-linked polyethylene where it was thin along the locking groove and abnormal loading of the cup because of improper seating of the liner in the shell at the time of the original procedure. This study was conducted with institutional review board approval and in compliance with HIPAA (Health Insurance Portability and Accountability Act) requirements at our institution. A seventy-four-year-old woman underwent a primary right total hip replacement through a posterior minimally invasive approach. The femoral component was a VerSys Advocate cemented stem (Zimmer, Warsaw, Indiana) with a satin surface finish, a 34-mm neck length, and a …

Surface Roughness of CoCr and ZrO2 Femoral Heads with Metal Transfer: A Retrieval and Wear Simulator Study

Metal transfer to femoral heads may result from impingement against the metallic acetabular shell following subluxation/dislocation, or when metallic debris enters the articulation zone. Such transfers roughen the head surface, increasing polyethylene wear in total hip replacements. Presently, we examined the surface roughness of retrieved femoral heads with metallic transfer. Profilometry revealed roughness averages in regions of metal transfer averaging 0.380 μm for CoCr and 0.294 μm for ZrO2 which were one order of magnitude higher than those from non-implanted controls. Scanning electron microscopy (SEM) revealed adherent transfers on these retrievals, with titanium presence confirmed by electron dispersive spectroscopy. Due to the concern for increased wear, metal transfer was induced on non-implanted heads, which were then articulated against flat polyethylene discs in multidirectional sliding wear tests. Increased polyethylene wear was associated with these specimens as compared to unaltered controls. SEM imaging provided visual evidence that the transfers remained adherent following the wear tests. Pre- and post-test roughness averages exceeded 1 μm for both the CoCr and ZrO2 heads. Overall, these results suggest that metal transfer increases the surface roughness of CoCr and ZrO2 femoral heads and that the transfers may remain adherent following articulation against polyethylene, leading to increased polyethylene wear.