Martin Vrbka

Fabrication and characterization of DLC coated microdimples on hip prosthesis heads

Diamond like carbon (DLC) is applied as a thin film onto substrates to obtain desired surface properties such as increased hardness and corrosion resistance, and decreased friction and wear rate. Microdimple is an advanced surface modification technique enhancing the tribological performance. In this study, DLC coated microdimples were fabricated on hip prosthesis heads and their mechanical, material and surface properties were characterized. An Electro discharge machining (EDM) oriented microdrilling was utilized to fabricate a defined microdimple array (diameter of 300 µm, depth of 70 µm, and pitch of 900 µm) on stainless steel (SS) hip prosthesis heads. The dimpled surfaces were then coated by hydrogenated amorphous carbon (a-C:H) and tetrahedral amorphous carbon (Ta-C) layers by using a magnetron sputtering technology. A preliminary tribology test was conducted on these fabricated surfaces against a ceramic ball in simulated hip joint conditions. It was found that the fabricated dimples were perpendicular to the spherical surfaces and no cutting-tools wear debris was detected inside the individual dimples. The a-C:H and Ta-C coatings increased the hardness at both the dimple edges and the nondimpled region. The tribology test showed a significant reduction in friction coefficient for coated surfaces regardless of microdimple arrays: the lowest friction coefficient was found for the a-C:H samples (µ = 0.084), followed by Ta-C (µ = 0.119), as compared to the SS surface (µ = 0.248).

In situ measurements of thin films in bovine serum lubricated contacts using optical interferometry

The aim of this study is to consider the relevance of in situ measurements of bovine serum film thickness in the optical test device that could be related to the function of the artificial hip joint. It is mainly focussed on the effect of the hydrophobicity or hydrophilicity of the transparent surface and the effect of its geometry. Film thickness measurements were performed using ball-on-disc and lens-on-disc configurations of optical test device as a function of time. Chromatic interferograms were recorded with a high-speed complementary metal-oxide semiconductor digital camera and evaluated with thin film colorimetric interferometry. It was clarified that a chromium layer covering the glass disc has a hydrophobic behaviour which supports the adsorption of proteins contained in the bovine serum solution, thereby a thicker lubricating film is formed. On the contrary, the protein film formation was not observed when the disc was covered with a silica layer having a hydrophilic behaviour. In this case, a very thin lubricating film was formed only due to the hydrodynamic effect. Metal and ceramic balls have no substantial effect on lubricant film formation although their contact surfaces have relatively different wettability. It was confirmed that conformity of contacting surfaces and kinematic conditions has fundamental effect on bovine serum film formation. In the ball-on-disc configuration, the lubricant film is formed predominantly due to protein aggregations, which pass through the contact zone and increase the film thickness. In the more conformal ball-on-lens configuration, the lubricant film is formed predominantly due to hydrodynamic effect, thereby the film thickness is kept constant during measurement.

Study of film formation in bovine serum lubricated contacts under rolling/sliding conditions

The aim of this study is to perform a detailed experimental analysis of lubricant film thickness of bovine serum within the contact between the artificial metal and ceramic heads (balls) and the glass disc to analyse the effect of proteins on film formation under various rolling/sliding conditions. Lubricant film observation of bovine serum solutions was carried out using an optical test rig. Chromatic interferograms were recorded with a high-speed CMOS digital camera and evaluated with thin film colorimetric interferometry. Film thickness was studied as a function of time. Under pure rolling conditions, film thickness increases with time as well as with rolling distance for all mean speeds and for both materials of the balls; however the metal ball always forms a thicker lubricating film in comparison to the ceramic ball. Under rolling/sliding conditions, when the disc is faster than the ball, the formation of lubricant film thickness is different compared to pure rolling conditions. At first, film thickness increases rapidly with a rolling/sliding distance for all mean speeds. When maximum film thickness is reached, then this effect is lost and film thickness starts to fall and finally, at the end of the measurement, film thickness drops down to a few nanometres. For the metal ball, maximum values of central film thicknesses are proportional to the mean speed; however this is not observed with the ceramic ball. An absolutely different formation of bovine serum film thickness is observed when the ball is faster than the disc. Under this condition, the protein layer is very thin for both materials of balls, and central film thickness reaches only about a few nanometres. Local protein spots are formed in a very small area of the contact zone and reach the thickness between 20 and 25 nm for the metal ball and 5 nm for the ceramic ball. From the performed experiments under rolling/sliding conditions, it is obvious that the formation of lubricant film thickness is markedly dependent on kinematic conditions acting in the contact, especially on the positive and negative slide-to-roll ratio and the mean speed. In addition, the material of the artificial head has a certain influence on the formation of bovine serum lubricating film.

Wear Analysis of Extracted Polyethylene Acetabular Cups Using a 3D Optical Scanner

ABSTRACT Wear analysis of total hip replacements (THRs) is considered one of the most relevant research areas helping to improve the longevity and overall design of THRs. The coordinate machine method (CMM) and Fourier profilometry are the most common methods for measuring THR wear. This article presents optical scanner digitalization as a new method for measuring the wear of polyethylene (PE) acetabular cups. The aim of this article is to explore the potential of this method for the PE wear measurements. Optical scans for the purposes of this study were produced using an ATOS Triple Scan 3D optical scanner. The optical scanner is efficient and it can measure a large number of points for polygonization and for further development of the preworn models. In this study, the scanner first generated point clouds on a sample of 13 retrieved ultra-high-molecular-weight polyethylene (UHMWPE) acetabular cups. Next, volumetric models of the cups were created by polygonizing the point clouds. Reverse engineering was used to develop models of the original acetabular cups using the geometry of the unworn parts of the retrieved cups. A comparison of the two models then showed the total volume of the PE debris. The optical scanning method was validated against the gravimetric method using three new acetabular cups that were worn out on a hip pendulum simulator. Validation shows that the optical scanning method is a valid method for wear analysis of the retrieved UHMWPE acetabular cups.

The effect of lubricant constituents on lubrication mechanisms in hip joint replacements

The aim of the present paper is to provide a novel experimental approach enabling to assess the thickness of lubricant film within hip prostheses in meaning of the contribution of particular proteins. Thin film colorimetric interferometry was combined with fluorescent microscopy finding that a combination of optical methods can help to better understand the interfacial lubrication processes in hip replacements. The contact of metal femoral head against a glass disc was investigated under various operating conditions. As a test lubricant, the saline solution containing the albumin and γ-globulin in a concentration 2:1 was employed. Two different mean speeds were applied, 5.7 and 22mm/s, respectively. The measurements were carried out under pure rolling, partial negative and partial positive sliding conditions showing that kinematic conditions substantially affects the formation of protein film. Under pure rolling conditions, an increasing tendency of lubricant film independently on rolling speed was detected, while the total thickness of lubricant film can be attributed mainly to albumin. When the ball was faster than the disc (negative sliding), a very thin lubricant film was observed for lower speed with no significant effect of particular proteins. The increase in sliding speed led to the increase of film thickness mainly caused due to the presence of γ-globulin. On the contrary, when the disc was faster than the ball (positive sliding), the film formation was very complex and time dependent while both of the studied proteins have shown any qualitative change during the test, however the effect of albumin seems to be much more important. Since a very good agreement of the results was obtained, it can be concluded that the approach consisting of two optical methods can provide the fundamental information about the lubricant film formation in meaning of particular proteins while the simultaneous presence of other constituents in model synovial fluid.

In situ observation of lubricant film formation in THR considering real conformity: The effect of diameter, clearance and material

The aim of the present study is to provide an analysis of protein film formation in hip joint replacements considering real conformity based on in situ observation of the contact zone. The main attention is focused on the effect of implant nominal diameter, diametric clearance and material. For this purpose, a pendulum hip joint simulator equipped with electromagnetic motors enabling to apply continuous swinging flexion-extension motion was employed. The experimental configuration consists of femoral component (CoCrMo, BIOLOX®forte, BIOLOX®delta) and acetabular cup from optical glass fabricated according to the dimensions of real cups. Two nominal diameters were studied, 28 and 36mm, respectively, while different diametric clearances were considered. Initially, a static test focused on the protein adsorption onto rubbing surfaces was performed with 36mm implants. It was found that the development of adsorbed layer is much more stable in the case of metal head, indicating that the adsorption forces are stronger compared to ceramic. A consequential swinging test revealed that the fundamental parameter influencing the protein film formation is diametric clearance. Independently of implant diameter, film was much thicker when a smaller clearance was considered. An increase of implant size from 28mm to 36mm did not cause a substantial difference in film formation; however, the total film thickness was higher for smaller implant. In terms of material, metal heads formed a thicker film, while this fact can be, among others, also attributed to clearance, which is more than two times higher in the case of ceramic implant.

Lubrication within hip replacements – Implication for ceramic-on-hard bearing couples

The objective of the present study is to clarify the lubrication processes within artificial joints considering the ceramic femoral heads focusing on the role of particular proteins. Two optical methods were employed; colorimetric interferometry and fluorescent microscopy. The experiments were conducted in ball-on-disc configuration, where the ball is made from ceramic (Sulox(TM), BIOLOX(®)delta) and the disc from optical glass. The measurements were realized under pure rolling, partial negative and partial positive sliding, to get a complex information about the protein film behaviour under various conditions. Moreover, two different speeds were investigated; 5.7 and 22 mm/s, respectively. The contact was lubricated by saline solutions containing albumin and γ-globulin in a ratio 2:1, while the total protein concentration was 10.5 mg/ml. Under pure rolling conditions, the film thickness gradually increases with time/rolling distance independently of material and rolling speed, while the dominant fluid constituent is albumin. In the case of negative sliding, the film formation is time/distance/speed dependent. At lower speed, both proteins contribute to film thickness; at higher speed, the effect of γ-globulin is not substantial. When the disc is faster, the character of film formation is similar to the metal component in the case of Sulox ceramic. Biolox ceramic shows a different behaviour, while for both materials, the contribution of γ-globulin increases with increasing speed. As most of the results can be well explained in terms of specific proteins, it can be concluded that the experimental approach is suitable for the investigation of protein film formation considering the ceramic materials.

Characteristics of synovial fluid required for optimization of lubrication fluid for biotribological experiments

Wear testing of total joint replacement (TJR) is mandatory in preclinical testing before implantation of TJR into the human body. Testing is governed by current international standards that recommend bovine serum (BS) as a lubricating fluid to replace synovial fluid (SF). Recently, the use of BS has been criticized because of differences in content, fluid characteristics, and nonhuman origin. As a result, a more realistic lubricant mimicking SF is needed. To define SF composition, we analyzed SF obtained during revisions of total hip and knee arthroplasties and compared it with SF obtained during primary arthroplasties and from patients without TJR. Samples were acquired from 152 patients. We found that the median total protein concentration for all SF was 36.8 mg/mL, which is significantly higher than concentrations currently recommended by the ISO standards. The γ-globulin concentration was significantly higher and the phospholipid concentration significantly lower in patients with revision of TJR compared with patients without TJR. No significant difference was found in hyaluronic acid concentration and viscosity among the groups. Our results support the need to improve the definition of a more clinically relevant wear testing lubricant in the ISO standards.

Towards near-permanent CoCrMo prosthesis surface by combining micro-texturing and low temperature plasma carburising

An advanced surface engineering process combining micro-texture with a plasma carburising process was produced on CoCrMo femoral head, and their tribological properties were evaluated by the cutting-edge pendulum hip joint simulator coupled with thin film colorimetric interferometry. FESEM and GDOES showed that precipitation-free C S-phase with a uniform case depth of 10μm was formed across the micro-textures after duplex treatment. Hip simulator tests showed that the friction coefficient was reduced by 20% for micro-metre sized texture, and the long-term tribological property of microtexture was enhanced by the C-supersaturated crystalline microstructure formed on the surface of duplex treated CoCrMo, thereby enhancing biotribological durability significantly. In-situ colorimetric interferometry confirmed that the maximum film thickness around texture area was 530nm, indicating that the additional lubricant during sliding motion might provide exceptional bearing life.

Effect of surface dents on contact pressure in elastohydrodynamic contacts

Abstract Nowadays film thickness measurement techniques can provide precise data for the detailed studies of the behaviour of lubricated contacts including transient operational conditions. Contact pressure is in relation with deformation of rubbing surfaces, which can be derived from experimentally evaluated film thickness. Even though the pressure distribution evaluated from measured film thickness is very sensitive to its accuracy, this approach represents a powerful tool for elastohydrodynamic pressure determination; thanks to the relative wide availability of film thickness measurement techniques. Chromatic interferograms can be captured within a few microseconds so that this approach seems to be promising in obtaining relevant pressure data even within non-smooth lubricated contacts. This article presents the results of the effort to extend the applicability of the pressure-film thickness evaluation approach to the non-smooth surfaces. It was found that the main problem is to obtain the film thickness distribution within the whole contact including the inside portion of the deep surface features (e.g. dents). That is why the combination of film thickness data and undeformed dent topography was suggested to overcome these limitations. This approach was validated through the comparison with numerical solution using dented surface and was tested on selected dented contacts operated under thin film and very thin film lubrication conditions.