Wear analysis of retrieved alumina heads and sockets of hip prostheses

Wear of retrieved ceramic THA components--four matched pairs retrieved after 5-13 years in service

Retrieval analyses of alumina-alumina THA components are conducted in order to investigate in vivo wear of implants and provide guidance to material and design improvements. The contribution of the present study consists of the examination, by digital recording of spherical profiles and scanning electron microscopy, of four matched pairs of ceramic THA implants retrieved after 5, 11, 13, and 13 years in service because of mechanical loosening. Maximum wear depth values on measured surfaces ranged between 10-325 microm for heads and 25-784 microm for cups, while grossly worn areas varied between 240 and 1510 mm(2) for heads and 250 and 1570 mm(2) for cups. The greatest wear characteristics were demonstrated by the pair that served for 5 years, that is, on the cup that was found in a 65 degrees inclination. Quantitative topographical study of the results provided concrete evidence of a cascade of detrimental wear events of changing geometry, intensity, and progression associated with gradual cup tilting. Microscopy findings support previously recognized wear mechanisms.

Differential apoptotic response of J774 macrophages to alumina and ultra-high-molecular-weight polyethylene particles

We recently identified apoptosis in in vitro wear particle-stimulated macrophages. The recent explosion of interest in apoptosis lies in the fact that it is under positive and negative regulation through evolutionary conserved biochemical pathways. It may also be possible to modulate macrophage apoptosis in the treatment of periprosthetic osteolysis. The purpose of this study was to compare the macrophage response to identically sized particles of alumina ceramic (Al2O3) and ultra-high-molecular-weight polyethylene (UHMWPE) in terms of TNF-alpha release and induction of apoptosis. J774 mouse macrophages were incubated for 0-24 h in the presence of Al2O3 and UHMWPE particles. TNF-alpha release was measured by ELISA; Poly(ADP-ribose)polymerase (PARP) and caspase-3 expression was analyzed by Western blot; DNA fragmentation (DNA laddering) was visualized on agarose gel containing ethidium bromide. Al2O3 particles induced TNF-alpha release after 4 h incubation with concentrations reaching 483 and 800 pg/ml after 24 h with 125 and 250 particles/macrophage, respectively (control = 161 pg/ml) (P < 0.05 vs. control). The same concentrations of UHMWPE particles induced a much larger and significant TNF-alpha release after only 1 h incubation, increasing up to 6250 pg/ml after 24 h (P < 0.05 vs. control). Western blot analysis demonstrated that the active caspase-3 fragment (17 kDa) and the proteolytic PARP fragment (85 kDa) were expressed after 2 h incubation with 125 and 250 Al2O3 particles/macrophage. The active caspase-3 and the PARP fragment had lower expression and appeared after a longer incubation time (8 h) with 125 and 250 UHMWPE particles/macrophage. Finally, DNA fragmentation (DNA laddering) was observed after 16 h with 125 and 250 particles of Al2O3 per macrophage whereas no laddering was induced by UHMWPE particles even after 24 h incubation. This study shows that although both Al2O3 and UHMWPE particles induce TNF-alpha release, this stimulation was much greater (8-10 times higher) with UHMWPE than Al2O3 (P < 0.05 vs. control). As well, the induction of apoptosis, as measured by activation of caspase-3, PARP cleavage and DNA laddering, is different for these two particles, being faster and more important with Al2O3 than UHMWPE. We hypothesize that the ability of Al2O3 to induce macrophage apoptosis may explain the lower TNF-alpha release observed with these particles and explain the differences seen in osteolysis patterns of ceramic-ceramic (CC) vs. metal-polyethylene (Mpe) articulations. In conclusion, apoptosis may be a major internal mechanism to decrease macrophage activity and may be a desired therapeutic endpoint. The identification of an apoptosis-related pathway in the macrophage response to ceramic particles provides crucial data for a rational approach in the treatment and/or prevention of periprosthetic osteolysis.

Wear of HIPed and non-HIPed alumina-alumina hip joints under standard and severe simulator testing conditions

Wear and the biological response to wear debris of artificial joints remain major concerns in total hip arthroplasty (THA). The long-term effects of UHMWPE wear debris are well documented and these have led to interest in alternate bearing materials for THA. Alumina ceramic-ceramic hip joints have been successfully used for more than 30 years with low wear and little incidence of osteolysis. The most common wear pattern observed on retrieved components is an elliptical wear 'stripe' on the heads and a corresponding worn area on the cup with an approximated wear rate of 1-5 mm3 pa. More severe wear has also occasionally occurred, usually in association with an abnormal clinical history. Modern alumina-alumina THAs use an improved HIPed (hot isostatically pressed) alumina ceramic-bearing material which may be more resistant to severe wear. Previous in vitro simulator studies have not replicated in vivo wear rates or mechanisms. The aim of this study was to compare previous generation non-HIPed alumina and modern HIPed alumina in a hip joint simulator under 'normal' and 'harsh' testing conditions. HIPed alumina was found to have a lower wear rate than non-HIPed alumina, although the difference was not statistically significant at the 95% confidence level. Testing in Gelofusine and water lubricants did not elevate the wear rates of either material. Elevated swing phase load testing also had no significant effect on the wear rates of either material. Testing in the absence of any lubricant produced very severe wear of the non-HIPed material in one specimen only.

Debris from failed ceramic-on-ceramic and ceramic-on-polyethylene hip prostheses

To compare the properties of wear debris between ceramic-on-ceramic and ceramic-on-polyethylene total hip prostheses, particles were isolated and characterized from tissue biopsies obtained at revision arthroplasty or autopsy from two similar uncemented modular hip systems. Group A hips (11 patients; mean, 31 months in vivo) had titanium shells with alumina inserts, alumina femoral heads, and titanium alloy stems. Group B hips (seven patients; mean, 42 months) were the same as Group A but with polyethylene acetabular inserts. Particles were characterized using an electrical resistance particle analyzer, scanning electron microscope, and energy dispersive xray spectroscope. Most of the particles in Group A were ceramic, whereas most of the particles in Group B were polyethylene. Metal particles from the femoral stem and the acetabular shell also were present. If one Group A hip with impingement is excluded, the rate of particle production is significantly lower in the ceramic-on-ceramic group than in the ceramic-on-polyethylene group. With the number of samples available, no significant difference in average size could be detected among the different types of particles or among the groups.

In vitro comparison of the two hard-hard articulations for total hip replacements

Polyethylene particle disease is one of the major causes of late aseptic loosening of total hip replacement. Two hard-hard articulations (alumina-on-alumina and metal-on-metal) have been developed in Europe as an alternative to the ultra-high molecular weight polyethylene (UHMWPE) articulations. Even though these hard-hard articulations are on the market and numerous reports have been published about them, only a very limited number of studies allowing a direct in vitro comparison of the two articulations have been published so far. This paper compares in vitro these two types of articulation (alumina-on-alumina and metal-on-metal), which have been tested with a hip simulator for their tribological behaviour using exactly the same experimental methodology. This comparison shows that these two types of hard-hard articulation have very similar abrasive wear behaviour with four main features: 1. A running-in wear period (1 x 10(6) cycles) gives a cumulative wear of about 20 microns with head diameters of 28 mm. 2. After the running-in wear, there is a stabilization of the linear wear behaviour with a low linear wear rate/10(6) cycles for both types of articulation. 3. The volumetric wear rate of both articulations (< 2.0 mm3/year for head diameters of 28 mm) is significantly lower than that observed for metal-on-polyethylene or ceramic-on-polyethylene articulations having the same head diameter. 4. Abrasive wear is readily apparent (indicating a mixed lubrication regime) with both types of articulation. The extremely low wear performance of these articulations is confirmed and they constitute a low-wear alternative to the UHMWPE articulations currently used.

Ceramic/ceramic total hip arthroplasty

Alumina-on-alumina total hip arthroplasty has been used for 30 years, mainly in Europe. The theoretical advantages of this combination are represented by its remarkable sliding characteristics, its very low wear debris generation, and its sufficient fracture toughness. These advantages are achieved if the material is properly controlled with high density, high purity, and small grains. The authors summarize the results obtained with ceramic/ceramic total hip arthroplasty. Information is provided about in vivo behavior regarding wear debris characterization and quantification, and histological tissue examinations for inflammatory reactions, which were not encountered except when alumina debris was mixed with metal or cement. Modification of socket fixation resulted in improved clinical outcomes. With a press-fit metal shell and an alumina liner utilized for 10 years, the results are excellent especially in a young and active population. Alumina-on-alumina seems at the moment to be one of the best choices when a total hip arthroplasty has to be performed in young and active patients.

A frictional study of total hip joint replacements

Polymeric wear debris produced by articulation of the femoral head against the ultra-high-molecular-weight polyethylene socket of a total hip replacement has been implicated as the main cause of osteolysis and subsequent failure of these implants. Potential solutions to this problem are to employ hard bearing surface combinations such as metal-on-metal or ceramic-on-ceramic prostheses. The aim of this study was to investigate the difference in lubrication modes and friction of a range of material combinations using synthetic and biological fluids as the lubricants. The experimental results were compared with theoretical predictions of film thicknesses and lubrication modes. A strong correlation was observed between experiment and theory when employing carboxy methyl cellulose (CMC) fluids as the lubricant. Under these conditions the ceramic-on-ceramic joints showed full fluid film lubrication while the metal-on-metal, metal-on-plastic, diamond-like carbon-coated stainless steel (DLC)-on-plastic and ceramic-on-plastic prostheses operated under a mixed lubrication regime. With bovine serum as the lubricant in the all ceramic joints, however, the full fluid film lubrication was inhibited due to adsorbed proteins. In the metal-on-metal joints this adsorbed protein layer acted to reduce the friction while in the ceramic coupling the friction was increased. The use of bovine serum as the lubricant also significantly increased the friction in both the metal-on-plastic and ceramic-on-plastic joints. The friction produced by the DLC-on-plastic joints depended on the quality of the coating. Those joints with a less consistent coating and therefore a higher surface roughness gave significantly higher friction than the smoother, more consistently coated heads.

Bioactivity of sol-gel bioactive glass coated alumina implants

Alumina on alumina total hip arthroplasty has been in use for more than 25 years with encouraging results. However, an improvement of the alumina/bone interface still is required. The objective of this study was to investigate the in vitro and in vivo osteoconductive properties of sol-gel bioactive glass coated alumina implants. Two sol-gel glass compositions (58S Bioglass(R) and 77S Bioglass(R)) were used as coatings on alumina substrates and implanted in a rabbit model. The 58S sol-gel coating was employed in two configurations, single (A58S1) and double layer (A58S2). SEM analysis after one week in simulated body fluid revealed small crystals assumed to represent the initial phase of hydroxyapatite formation, whereas no clear conclusion could be drawn from Fourier transform infrared spectroscopy data. The percentage of bone in direct contact was greater for coated implants when compared to bulk alumina implants (p <0.001). In the case of A58S1 implants, bone percentage significantly increased from 45.1% after 3 weeks up to 87. 8% after 24 weeks of implantation (p = 0.0004). The presence of osteoid tissue, related to an aluminum release from the alumina substrates, was greatly diminished when compared to melt-derived glass-coated alumina implants.

Wear of alumina-on-alumina total hip arthroplasties at a mean 11-year followup

The surface topography of 11 alumina-on-alumina hip arthroplasties retrieved for aseptic loosening at a mean 11-year followup was investigated. Macroscopic wear was assessed using a coordinate measuring machine. Microscopic wear features were evaluated by Talysurf analysis. Scanning electron microscopy was used to look at the alumina microstructure. Components were classified into three groups: (1) low wear with no sign of wear and average arithmetic roughness values below 0.05 microm; (2) stripe wear with a visible oblong worn area on the femoral heads and penetration rates below 10 microm/year; and (3) severe wear with a visible loss of material on both components, showing total roughness values as much as 4 microm and maximum penetrations higher than 150 microm. Alumina quality assessed by grain size measurements and porosity percentages improved progressively from 1977 to 1988. This resulted in a correlated decrease of the microscopic wear magnitude. However, on a macroscopic scale, factors responsible for either a load increase (weight, young age, and male gender) or impairment in the load distribution over the component surfaces (large grain size, nonoptimal initial cup inclination, and cup migration and/or tilting) increased the penetration rates.

Alumina-on-alumina total hip prostheses in patients 40 years of age or younger

To avoid the consequences of polyethylene wear in a high-risk population, 128 alumina-on-alumina total hip arthroplasties have been done in 104 consecutive patients. The maximum age of patients was 40 years. The main preoperative diagnoses were osteonecrosis and sequellae of congenital hip dislocation (71% of the hips). The same titanium alloy cemented stem was implanted in all of the hips. Four types of alumina acetabular component fixations were used: a cemented plain alumina socket (41 hips), a screw-in ring with an alumina insert (22 hips), a press-fit plain alumina socket (32 hips), and a press-fit titanium metal back with an alumina insert (33 hips). Eight patients (11 hips) died during the followup period. Sixteen revisions have been documented, 12 for acetabular aseptic loosening, three for bipolar loosening (two of which were septic), and one for unexplained pain. Eighty-eight hips in 74 patients have been followed up radiologically for 2 to 22 years. Wear was unmeasurable. Four additional sockets showed definite migration. The respective survival rates after 7 years were 94.1% for the cemented cup, 88.8% for the screw-in ring, 95.1% for cementless press-fit plain alumina socket and 94.3% for the metal-back press-fit component. The 10-year survival rate was 90.4% for the cemented socket and 88.8% for the screw-in ring. The 15-year survival rate was 78.9% for the cemented socket. Grafting was the only prognostic factor, with a survival rate of 62.6% after 10 years for the hips with a bone graft and of 90.1% for hips without a graft. The alumina-on-alumina bearing surfaces seem to be a valuable alternative to the standard metal-on-polyethylene system for young patients. However, an improvement in socket fixation is required to lengthen the life span of the prosthesis to match the life expectancy of this demanding population.

Biological reactions to wear debris in total joint replacement

The vast majority of total hip prostheses currently implanted consist of a hard metal or ceramic femoral head articulating against an ultra-high molecular weight polyethylene (UHMWPE) acetabular cup. Over the last 10 years, evidence has accumulated to show that these prostheses are prone to failure due to late aseptic loosening and few survive beyond 25 years. With an increasing need to implant hip prostheses in the younger, more active patient the need to understand the mechanisms of failure and to develop artificial hip joints using alternative materials have become major issues in the orthopaedic community. This review focuses initially on our current understanding of the biological reactions to UHMWPE prosthetic wear debris in vivo and in vitro since this is believed to be the main cause of late aseptic loosening. While the precise mechanisms of osteolysis induced by UHMWPE wear debris have not been elucidated, the major message to emerge is that it is not the wear volume that determines the biological response to the debris, but the concentration of the wear volume that is within the critical size range (0.2-0.8 micron) for macrophage activation. The review then considers whether the problem of wear-debris-induced osteolysis may be overcome with the use of new generation metal-on-metal or ceramic-on-ceramic prostheses. For metal-on-metal prostheses, the prospects for increasing the osteolysis free life of the implant are good but additional biological problems associated with the nanometre size and reactivity of the wear particles in vivo may emerge. For the ceramic-on-ceramic prostheses, although initial prospects are encouraging, more data are needed on the characteristics of the wear particles generated in vivo before predictions can be made. It is concluded that the pre-clinical testing of any new materials for joint replacement must include an analysis of the wear particle characteristics and their biological reactivity in addition to the usual assessment of wear.

A comparative joint simulator study of the wear of metal-on-metal and alternative material combinations in hip replacements

While total hip replacement represents the major success story in orthopaedic surgery in the twentieth century, there is much interest in extending even further, early in the twenty first century, the life of implants. Osteolysis has been identified as a major factor limiting the life of prostheses, with indications that fine polyethylene wear debris, generated primarily at the interface between the femoral head and the acetabular cup, promotes the process. There is therefore considerable interest in the introduction of alternative wear resistant systems to limit the deleterious effects of wear. These alternatives include ceramic-on-ceramic and metal-on-metal configurations and the present paper is primarily concerned with the latter. Some six pairs of new metal-on-metal implants of 36 mm diameter and four pairs of existing metal-on-metal implants of 28 mm diameter were tested in a ten-station hip joint simulator in the presence of a 25 per cent bovine serum solution. The implants were tested in the anatomical position to 5 x 10(6) cycles. The new heads and cups were manufactured from CoCrMo alloy with careful attention being paid to sphericity and surface finish of both components. The wear performance of the new and existing metal-on-metal total hip replacements have been evaluated and compared. The overall wear rates have then been compared with previously reported wear rates for a zirconia-on-polyethylene prosthesis of 22 mm diameter tested on the same simulator. The comparison is taken further by recalling published penetration data for metal-on-polyethylene implants of 22 and 28 mm diameter and converting these to volumetric wear rates. It was found that the heads and cups in metal-on-metal joints wore by almost equal amounts and that the opposing surfaces converged to similar surface roughness as the testing time increased. Steady state wear rates were generally achieved after 1-2 x 10(6) cycles. The mean long-term wear rates for the metal-on-metal prostheses were very low, being 0.36 mm3/10(6) cycles and 0.45 mm3/10(6) cycles for the new implants of 36 mm diameter and established implants of 28 mm diameter respectively. These wear rates compare with 6.3 mm3/10(6) cycles for zirconia-on-ultra-high molecular weight polyethylene tested on the same simulator and representative clinical values for metal-on-polyethylene of 36 mm3/year for heads of 22 mm diameter and a reported range of 60-180 mm3/year for 28 mm heads. These values do not translate directly into numbers of particles, since the metallic debris from metal-on-metal joints is very fine. The number of metallic particles may exceed the number of polyethylene wear particles from an otherwise similar metal-on-polyethylene joint by a factor of 10(3). A detailed discussion of the size and morphology of wear debris and tissue reaction to various forms of debris is beyond the scope of this paper, but the biological response to polymeric, metallic and ceramic wear debris forms a major subject for further study. The present investigation nevertheless confirms the potential of carefully designed and manufactured metal-on-metal total replacement joints for the treatment of diseased and damaged hips.

Cementless bulk alumina socket: preliminary results at 6 years

To avoid polyethylene wear observed in total hip replacement, an alumina-alumina combination has been used since 1977. The aim of this study is to report the results of a hybrid alumina-alumina total hip arthroplasty with a cementless press-fit bulk alumina socket and a cemented titanium alloy stem in 55 patients (62 hips) operated on between 1982 and 1990. The bearing surfaces were a 32-mm alumina head articulating within the alumina socket. Four failures occurred: 3 aseptic loosenings of the socket and 1 femoral head fracture. Considering aseptic loosening as the endpoint, the survival rate was 93.2% after 6 years. At a mean of 72.1 months' follow-up, 92.4% of the surviving hips were graded as very good or good using the Merle d'Aubigné-Postel hip score. Radiolucent lines were observed on the acetabular side in 68.1 of the hips. The future of this interface, which is probably fibrous, remains questionable. With the exception of 1 femoral head fracture, all revisions were related to failure of the bony fixation of the socket, and no problem was encountered related to the alumina-alumina friction coupling. Alumina sockets with other types of cementless fixation have therefore been designed and are presently under clinical investigation.

[TNF-alpha secretion by human macrophage-like cells in response to wear particles and its modification by drugs]

Tumour necrosis factor (TNF) is considered to be the initiator protein of particle disease leading to aseptic loosening of endoprostheses. The aim of the present study was to investigate the TNF response of the macrophage-like cells (MLC) to the periprosthetic particles typically found during revision surgery. For this purpose, particles of polyethylene (PE), pure titanium (Ti), chromium (Cr), cobalt (Co), alumina ceramic (Al2O3) and zirconium dioxide (ZrO2) were used. Additionally, the therapeutic effect of non-steroidal and steroidal drugs, biphosphonates and pentoxyfylline on PE particles was investigated with the aim of differentiating drugs with, from those without, a positive effect on aseptic loosening.

METHOD

In an established macrophage model (Rader et al. 1999), THP1 cells (human monocytic cell line) were differentiated over a period of five days in the presence of vitamin D3 and GM-CSF in macrophage-like cells (MLC). To obtain a TNF profile of the different materials, 10(6) MLC were incubated with each of a range of different particle concentrations. For drug testing purposes 80 x 10(8) PE particles, which evoked a maximum TNF response, were applied together with increasing drug concentrations in the same manner. The supernatant was then investigated for TNF secretion using ELISA.

RESULTS

It was found that the greatest TNF response was provoked by Co and PE particles, and was 25 and 23 times as high, respectively, in comparison with control. The smallest TNF secretion was seen with Al2O3 (4 x control) and ZrO2 (5 x control). At the recommended dose, non-steroidal anti-inflammatory drugs (NSAIDs) produced no decrease in TNF secretion. The biphosphonates, etidronate and ibendronate significantly reduced the TNF response of the PE-stimulated macrophages (by 1/7 and 1/5, respectively). Therapeutic doses of pentoxyfylline also led to a decrease of 1/5 in maximum TNF release.

CONCLUSION

Ceramic articulating surfaces are superior to metal/metal or PE/PE matings in terms of the biological effects of their wear particles. At therapeutic doses, NSAIDs have no beneficial effect on the process of aseptic loosening. Certain biphosphonates and pentoxyfylline have a positive effect on aseptic loosening.

Flow cytometric analysis of macrophage response to ceramic and polyethylene particles: effects of size, concentration, and composition

Using the J774 macrophage cell line, we designed an in vitro model to analyze by flow cytometry the effects of size, concentration, and composition of ceramic (Al2O3 and ZrO2) and high density polyethylene (HDP) particles on phagocytosis and cell mortality. Inflammatory mediator (TNF-alpha) also was measured by ELISA. Kinetic studies revealed that phagocytosis of the particles begins very early after cell exposure, increasing with time and particle concentration and reaching a plateau after 15 h. This implies that the optimum period to evaluate cellular response to particulate debris is between 15 and 24 h of incubation. Results also showed that phagocytosis increases with concentration for particles up to 2 microns. For larger particles (up to 4.5 microns), phagocytosis seems to reach a plateau independent of size and concentration, which suggests a saturation of phagocytosis that is most likely dependent on overall particle volume ingested. We did not detect any significant difference in phagocytosis between Al2O3 and ZrO2 at 0.6 microns. Al2O3 seems to be more easily phagocytosed than HDP at the same size (4.5 microns) and concentrations. Cytotoxicity studies revealed that macrophage mortality increases with particle size and concentration for sizes greater than 2 microns. Smaller particles (0.6 microns) cause cell mortality only at higher concentrations (from 1,250 particles per cell), but the mortality is still very low (10%). No significant difference in cell mortality and TNF-alpha release was found between Al2O3 and ZrO2. Effects of Al2O3 and HDP at 4.5 microns were compared by measuring TNF-alpha release. Results showed that TNF-alpha release increases with particle concentrations and is higher with HDP than with Al2O3.

Evaluation of metal ion release and corrosion resistance of ZrO2 thin coatings on the dental Co-Cr alloys

OBJECTIVES

The aim of this study was to determine if electrolytic ZrO2 thin coatings increased the corrosion resistance and decreased the metal ion release of dental cobalt-chromium alloys.

METHODS

Dental Co-Cr alloys were electrolytically deposited with ZrO2 ceramic coatings using a 0.0625 M ZrO(NO3)2 solution, at various potentials, for 500 s. The electrolytic ZrO2 gel-coated specimens were annealed at 723 K for 1 h in air. Scanning electron microscopy (SEM) was used to observe the morphology of the ZrO2 ceramic coatings on Co-Cr alloys. A dynamic polarization test was used to compare the corrosion resistance of the ZrO2 coated and uncoated Co-Cr alloys in artificial saliva. Metal ion concentrations were determined with graphite furnace atomic absorption spectroscopy (AAS).

RESULTS

The SEM micrographs showed that the Co-Cr alloy can be coated with zirconia oxide at -0.7 V more homogeneously and more completely than at -1.5 V. The polarization curves indicated that the ZrO2 coating on Co-Cr alloys annealed at 723 K for 1 h in air exhibited better corrosion resistance in artificial saliva. The results of the AASs showed that the ZrO2-coated Co-Cr alloys decreased chromium ion release levels, as compared with the uncoated Co-Cr alloys. The scratch test indicated a good bond strength between the ZrO2 and Co-Cr alloy.

SIGNIFICANCE

The electrolytically deposited ZrO2 coatings on Co-Cr alloys may improve the corrosion resistance and decrease the release of metal ions. It is suggested that the electrolytic ZrO2 coating method could have a widespread application in dentistry in the future.

Analysis of fluid film lubrication in artificial hip joint replacements with surfaces of high elastic modulus

Lubrication mechanisms and contact mechanics have been analysed for total hip joint replacements made from hard bearing surfaces such as metal-on-metal and ceramic-on-ceramic. A similar analysis for ultra-high molecular weight polyethylene (UHMWPE) against a hard bearing surface has also been carried out and used as a reference. The most important factor influencing the predicted lubrication film thickness has been found to be the radial clearance between the ball and the socket. Full fluid film lubrication may be achieved in these hard/hard bearings provided that the surface finish of the bearing surface and the radial clearance are chosen correctly and maintained. Furthermore, there is a close relation between the predicted contact half width and the predicted lubrication film thickness. Therefore, it is important to analyse the contact mechanics in artificial hip joint replacements. Practical considerations of manufacturing these bearing surfaces have also been discussed.

Characterization of in vivo wear debris from ceramic-ceramic total hip arthroplasties

In contrast to the much-studied mechanism of aseptic loosening of the metal-polyethylene joint couple, the mechanism responsible for failure of ceramic-ceramic (CC) total hip arthroplasties (THAs) has not been evaluated. The aim of this study was to conduct a systematic characterization of the in vivo wear debris from 15 cases of CC THAs revised for aseptic loosening. Two methods were used to evaluate the wear debris; a semiquantitative histological analysis of H&E-stained periprosthetic pseudomembranes; and an evaluation of isolated debris particles using SEM, energy-dispersive X-ray analysis, and image analysis. The three main types of particulate debris identified were titanium alloy (TiAlV) and alumina ceramic (Al2O3) of prosthetic origin, and zirconium dioxide (ZrO2) from the contrast agent used in the cement for prosthetic fixation. Alumina debris was present in the smallest proportion (12%) and was consistent with the low wear rate of the CC joint couple. Zirconium dioxide debris was present in the greatest proportion (76%) and was an unexpected finding. The ZrO2 debris represented microstructural grains of the original ZrO2 particles added as contrast agent to the cement. The presence of a histiocytic foreign body reaction to ZrO2 debris on histologic sections leads us to believe that these particles play an important role in aseptic loosening of the CC THAs evaluated in this study.

Ceramic femoral head fractures in total hip arthroplasty

A failure analysis was performed of 4341 alumina ceramic heads articulating with 2693 alumina ceramic and 1464 polymer sockets implanted over 20 years (1974 to 1994). From 1974 to 1982, a mushroom shaped head with ceramic neck was used in 1069 cases, and from 1982 to 1994 a ball type head was used in 3272 cases. In the ceramic/ceramic cases, the average followup was 11 years, and in the polymer pairing cases, the average followup was 6 years. In ceramic self pairing with the mushroom shaped head, the fracture rate was 0.4% (5 of 1069). With the ball type head, the fracture rate was 0.06% (1 of 1763). In articulation with polymer sockets, only 1 head fracture occurred (0.07%). In the group of cases with ceramic/ceramic pairing, the reason for fracture was direct trauma in 4 cases, recurrent neck impingement in 2 cases, and fatigue failure in 1 case. The only case with ceramic head fracture in polymer pairing also was caused by direct trauma. Fractures of the alumina ceramic heads cannot be avoided, but the use of ball type neckless heads brought the fracture rate close to 0. Under the aspect of material safety, it seems to be possible to use the great advantage of the superior low wear of the alumina/alumina couple with negligible fracture risk.

Bone demineralization induced by cementless alumina-coated femoral stems

The biologic compatibility of ceramic materials has been widely demonstrated, and alumina (Al2O3) has been used extensively in clinical applications for nearly 20 years. The authors examined the behavior of bone tissue adjacent to the alumina coating in eight cementless hip prosthetic stems that appeared radiologically stable and were explanted because of pain. Histologic evaluation demonstrated the presence of a consistent layer of decalcified bone tissue in continuity with and parallel to the prosthetic interface. Based on laboratory findings, the authors attribute this demineralization phenomenon to a high local concentration of aluminum ions with metabolic bone disease, which is histologically comparable to the osteomalacic osteodystrophy described in dialysis patients. These findings must be carefully considered given the potential long-term implications for alumina-coated implants.

Size and shape of biomaterial wear debris

A literature review of wear debris is presented. Included are debris retrieved at revision of total joint replacement and at autopsy, as well as debris produced in vitro in wear testers and joint simulators or otherwise fabricated for biological experiments. Observations of wear debris in vivo and in vitro are classified in tabular form according to material type, origin, size, shape and color. Polymer particles, most commonly ultra-high molecular weight polyethylene (UHMWPE), exhibit the largest size range and appear as granules, splinters or flakes, while ceramic particles possess the smallest size range and have a granular structure. Metal particles seen in vivo and in vitro, whether from cobalt-chromium alloys or, less frequently, other alloys, form granular or needle-like shapes and generally are smaller than polymer particles but larger than ceramic particles. Particles generated in joint simulators resemble the size and shape of in vivo wear particles from total joint replacement (TJR) retrieved at revision or autopsy. However, particles prepared in vitro, whether in simulators or by other means, do not consistently resemble wear debris particles from TJR.

Examination of alumina ceramic components from total hip arthroplasties

Materials analysis has been conducted on retrieved Mittelmeier-Autophor ceramic components from total hip arthroplasties, correlating articulating surface wear morphology with clinical reasons for failure. Plastically deformed, agglomerated wear debris (30-60 microns) has been identified on femoral head articulation wear surfaces, displaying exaggerated wear, especially during the initiation stage. Such surfaces were associated with clinical failures involving displacement of the acetabular cup and perforation of the cortex by the femoral stem. It is thought that this wear debris may play an important role in the promotion of the 'avalanche' wear mechanism, as it is adherent and thus difficult to remove from the wear interface.