Fretting corrosion accelerates crevice corrosion of modular hip tapers

Adverse local tissue reaction arising from corrosion at the femoral neck-body junction in a dual-taper stem with a cobalt-chromium modular neck

BACKGROUND

Femoral stems with dual-taper modularity were introduced to allow additional options for hip-center restoration independent of femoral fixation in total hip arthroplasty. Despite the increasing availability and use of these femoral stems, concerns exist about potential complications arising from the modular neck-body junction.

METHODS

This was a multicenter retrospective case series of twelve hips (eleven patients) with adverse local tissue reactions secondary to corrosion at the modular neck-body junction. The cohort included eight women and three men who together had an average age of 60.1 years (range, forty-three to seventy-seven years); all hips were implanted with a titanium-alloy stem and cobalt-chromium-alloy neck. Patients presented with new-onset and increasing pain at a mean of 7.9 months (range, five to thirteen months) following total hip arthroplasty. After serum metal-ion studies and metal artifact reduction sequence (MARS) magnetic resonance imaging (MRI) revealed abnormal results, the patients underwent hip revision at a mean of 15.2 months (range, ten to twenty-three months). Tissue specimens were examined by a single histopathologist, and the retrieved implants were studied with use of light and scanning electron microscopy.

RESULTS

Serum metal levels demonstrated greater elevation of cobalt (mean, 6.0 ng/mL) than chromium (mean, 0.6 ng/mL) or titanium (mean, 3.4 ng/mL). MRI with use of MARS demonstrated adverse tissue reactions in eight of nine patients in which it was performed. All hips showed large soft-tissue masses and surrounding tissue damage with visible corrosion at the modular femoral neck-body junction. Available histology demonstrated large areas of tissue necrosis in seven of ten cases, while remaining viable capsular tissue showed a dense lymphocytic infiltrate. Microscopic analysis was consistent with fretting and crevice corrosion at the modular neck-body interface.

CONCLUSIONS

Corrosion at the modular neck-body junction in dual-tapered stems with a modular cobalt-chromium-alloy femoral neck can lead to release of metal ions and debris resulting in local soft-tissue destruction. Adverse local tissue reaction should be considered as a potential cause for new-onset pain in patients with these components, and early revision should be considered given the potentially destructive nature of these reactions. A workup including serologic studies (erythrocyte sedimentation rate and C-reactive protein), serum metal levels, and MARS MRI can be helpful in establishing this diagnosis.

Ten-year outcome of serum metal ion levels after primary total hip arthroplasty: a concise follow-up of a previous report*

We previously reported on the metal ion concentrations of cobalt, chromium, and titanium that were found in the serum of patients three years after they had undergone primary total hip arthroplasty as compared with the concentrations found in the serum of control patients who did not have an implant. This study is a concise update on the serum metal levels found in a cohort of these patients ten years after the time of hip implantation. Of the original seventy-five subjects, metal ion levels were available for forty patients (53%). Ten patients (hybrid group) had received a hybrid total hip replacement that consisted of a modular cobalt-alloy femoral stem with a cobalt-alloy femoral head that had been inserted with cement and a titanium acetabular socket that had been inserted without cement. Nine patients (cobalt-chromium [CoCr] group) had received an implant with an extensively porous-coated modular cobalt-alloy femoral stem and femoral head along with a titanium acetabular socket; the femoral and acetabular components had each been inserted without cement. Eight patients (titanium group) had undergone insertion of a proximally porous-coated modular titanium-alloy femoral stem with a cobalt-alloy femoral head and a titanium acetabular socket; the femoral and acetabular components had each been inserted without cement. Thirteen patients (control group) from the original control group of patients who had not received an implant served as control subjects. Serum metal levels were measured with use of high-resolution sector field inductively coupled plasma mass spectrometry. The hybrid total hip arthroplasty group had mean cobalt levels that were 3.2 times higher at 120 months than they were at baseline, and the cobalt levels in that group were significantly higher than those in the titanium total hip arthroplasty group at thirty-six, sixty, eighty-four, ninety-six, and 120 months (p < 0.01). The hybrid group had mean chromium levels that were 3.9 times higher at 120 months than they were at baseline, and the CoCr total hip arthroplasty group had chromium levels that were 3.6 times higher at 120 months than they were at baseline. The serum titanium levels were higher in the titanium group at all follow-up time intervals as compared with the levels in all other groups, and the level in the titanium group at 120 months was eighteen times higher than it was at baseline (p < 0.01). Patients with well-functioning primary metal-on-polyethylene total hip replacements had elevated serum metal levels for as many as ten years postoperatively. Furthermore, metal release at the modular femoral head-neck junctions, rather than passive dissolution from porous ingrowth surfaces, was likely the dominant source of serum cobalt and chromium.

Corrosion at the head-neck taper as a cause for adverse local tissue reactions after total hip arthroplasty

BACKGROUND

Corrosion at the modular head-neck junction of the femoral component in total hip arthroplasty has been identified as a potential concern, although symptomatic adverse local tissue reactions secondary to corrosion have rarely been described.

METHODS

We retrospectively reviewed the records of ten patients with a metal-on-polyethylene total hip prosthesis, from three different manufacturers, who underwent revision surgery for corrosion at the modular head-neck junction.

RESULTS

All patients presented with pain or swelling around the hip, and two patients presented with recurrent instability. Serum cobalt levels were elevated prior to the revision arthroplasty and were typically more elevated than were serum chromium levels. Surgical findings included large soft-tissue masses and surrounding tissue damage with visible corrosion at the femoral head-neck junction; the two patients who presented with instability had severe damage to the hip abductor musculature. Pathology specimens consistently demonstrated areas of tissue necrosis. The patients were treated with debridement and a femoral head and liner exchange, with use of a ceramic femoral head with a titanium sleeve in eight cases. The mean Harris hip score improved from 58.1 points preoperatively to 89.7 points at a mean of 13.0 months after the revision surgery (p=0.01). Repeat serum cobalt levels, measured in six patients at a mean of 8.0 months following revision, decreased to a mean of 1.61 ng/mL, and chromium levels were similar to prerevision levels. One patient with moderate hip abductor muscle necrosis developed recurrent instability after revision and required a second revision arthroplasty.

CONCLUSIONS

Adverse local tissue reactions can occur in patients with a metal-on-polyethylene bearing secondary to corrosion at the modular femoral head-neck taper, and their presentation is similar to the adverse local tissue reactions seen in patients with a metal-on-metal bearing. Elevated serum metal levels, particularly a differential elevation of serum cobalt levels with respect to chromium levels, can be helpful in establishing this diagnosis.

Corrosion at the neck-stem junction as a cause of metal ion release and pseudotumour formation

We present a series of 35 patients (19 men and 16 women) with a mean age of 64 years (36.7 to 75.9), who underwent total hip replacement using the ESKA dual-modular short stem with metal on-polyethylene bearing surfaces. This implant has a modular neck section in addition to the modular head. Of these patients, three presented with increasing post-operative pain due to pseudotumour formation that resulted from corrosion at the modular neck-stem junction. These patients underwent further surgery and aseptic lymphocytic vaculitis associated lesions were demonstrated on histological analysis. Retrieval analysis of two modular necks showed corrosion at the neck-stem taper. Blood cobalt and chromium levels were measured at a mean of nine months (3 to 28) following surgery. These were compared with the levels in seven control patients (three men and four women) with a mean age of 53.4 years (32.1 to 64.1), who had an identical prosthesis and articulation but with a prosthesis that had no modularity at neck-stem junction. The mean blood levels of cobalt in the study group were raised at 50.75 nmol/l (5 to 145) compared with 5.6 nmol/l (2 to 13) in control patients. Corrosion at neck-stem tapers has been identified as an important source of metal ion release and pseudotumour formation requiring revision surgery. Finite element modelling of the dual modular stem demonstrated high stresses at the modular stem-neck junction. Dual modular cobalt-chrome hip prostheses should be used with caution due to these concerns.

Fretting corrosion of CoCrMo and Ti6Al4V interfaces

Mechanically assisted corrosion (fretting corrosion, tribocorrosion etc.,) of metallic biomaterials is a primary concern for numerous implant applications, particularly in the performance of highly-loaded medical devices. While the basic underlying concepts of fretting corrosion or tribocorrosion and fretting crevice corrosion are well known, there remains a need to develop an integrated systematic method for the analysis of fretting corrosion involving metal-on-metal contacts. Such a method can provide detailed and quantitative information on the processes present and explore variations in surfaces, alloys, voltages, loadings, motion and solution conditions. This study reports on development of a fretting corrosion test system and presents elements of an in-depth theoretical fretting corrosion model that incorporates both the mechanical and the electrochemical aspects of fretting corrosion. To demonstrate the capabilities of the new system and validate the proposed model, experiments were performed to understand the effect of applied normal load on fretting corrosion performance of Ti6Al4V/Ti6Al4V, CoCrMo/Ti6Al4V, and CoCrMo/CoCrMo material couples under potentiostatic conditions with a fixed starting surface roughness. The results of this study show that fretting corrosion is affected by material couples, normal load and the motion conditions at the interface. In particular, fretting currents and coefficient of friction (COF) vary with load and are higher for Ti6Al4V/Ti6Al4V couple reaching 3 mA/cm(2) and 0.63 at about 73 MPa nominal contact stress, respectively. Ti6Al4V coupled with CoCrMo displayed lower currents (0.6 mA/cm(2)) and COF (0.3), and the fretting corrosion behavior was comparable to CoCrMo/CoCrMo couple (1.2 mA/cm(2) and 0.3, respectively). Information on the mechanical energy dissipated at the interface, the sticking behavior, and the load dependence of the inter-asperity distance calculated using the model elucidated the influence of mechanical factors on the experimental results. It was observed that the lowest amount of work was required to generate some of the highest fretting corrosion currents in Ti6Al4V/Ti6Al4V couples compared to the other combinations. The elements of the model presented here provide an excellent basis to explain many of the observed behaviors of these interfaces.

Evaluation and treatment of painful total hip arthroplasties with modular metal taper junctions

Modern primary total hip arthroplasty femoral components have evolved to include modular necks. Subsequently, the additional taper junction provides another interface as a potential source for mechanically assisted crevice corrosion, which is a complex process involving fretting and crevice corrosion. Furthermore, it is becoming evident that an adverse local tissue reaction may result in some patients due to the mechanically assisted crevice corrosion. This article details the clinical, radiographic, and laboratory evaluation of patients with these components who present with persistent pain. The relevant surgical strategies and techniques to address this pathology in symptomatic patients are addressed.

Modularity of the femoral component in total hip arthroplasty

Modular femoral components have been developed to aid in recreating native femoral version, limb length, and offset in total hip arthroplasty. Use of modular implants results in cost savings, as well. Inventory can be reduced while allowing intraoperative flexibility and options. With modular implants, the femoral prosthesis can be built in situ, which is helpful in minimizing incision length and surgical dissection. However, additional modular junctions are associated with increased concern for component failure through taper fretting, fatigue fracture, and local corrosion, which may contribute to elevated serum metal ion levels. The recent trend toward using larger diameter femoral heads may impart higher loads and stress than were seen previously. Although modular components offer a plethora of intraoperative options in primary and revision total hip arthroplasty, the long-term effects of these additional junctions remains unknown.

Corrosion fatigue of biomedical metallic alloys: mechanisms and mitigation

Cyclic stresses are often related to the premature mechanical failure of metallic biomaterials. The complex interaction between fatigue and corrosion in the physiological environment has been subject of many investigations. In this context, microstructure, heat treatments, plastic deformation, surface finishing and coatings have decisive influence on the mechanisms of fatigue crack nucleation and growth. Furthermore, wear is frequently present and contributes to the process. However, despite all the effort at elucidating the mechanisms that govern corrosion fatigue of biomedical alloys, failures continue to occur. This work reviews the literature on corrosion-fatigue-related phenomena of Ti alloys, surgical stainless steels, Co-Cr-Mo and Mg alloys. The aim was to discuss the correlation between structural and surface aspects of these materials and the onset of fatigue in the highly saline environment of the human body. By understanding such correlation, mitigation of corrosion fatigue failure may be achieved in a reliable scientific-based manner. Different mitigation methods are also reviewed and discussed throughout the text. It is intended that the information condensed in this article should be a valuable tool in the development of increasingly successful designs against the corrosion fatigue of metallic implants.

Cushion bearings versus large diameter head metal-on-metal bearings in total hip arthroplasty: a short-term metal ion study

INTRODUCTION

Metal-on-metal total hip arthroplasty (MOM THA) has the advantage of replicating the femoral head size, but the postoperative elevation of serum metal ion levels is a cause for concern. Metal-on-polycarbonate-urethane is a new cushion bearing featuring a large diameter metal head coupled with a polycarbonate-urethane liner.

AIM

The aim of this study was to assess and compare serum cobalt (Co) and chromium (Cr) levels in a group of 15 patients treated with a cushion bearing THA system (Group A) and a group of 15 patients treated with a MOM THA system (Group B) at short-term. At a mean follow-up of 27.3 months (18-35 months), in Group A the median Cr and Co serum levels were significantly lower than in Group B, measuring 0.24 μg/L (0.1-2.1 μg/L) and 0.6 μg/L (0.29-2.3 μg/L) compared to 1.3 μg/L (0.1-9 μg/L, p < 0.001) and 2.9 μg/L (0.85-13.8 μg/L, p < 0.001) respectively.

RESULTS

All patients demonstrated an excellent clinical result, as shown by the Harris and Oxford hip scores. The cushion bearing THA studied in this paper showed clinical outcomes similar to the MOM THA bearing, with the advantage of no significant metal ion elevation in the serum.

CONCLUSION

These findings warrant the continued clinical study of compliant bearing options.

Factors to consider in joint prosthesis systems

In joint reconstruction, the techniques and materials that provide the best outcomes for patients have been debated. The main points of controversy relate to the use of hemiarthroplasties versus total joint prostheses with metal-on-metal versus metal-on-polyethylene articulations. This article investigates these areas as well as the applicability of the techniques and materials and the complications that can occur. Hypersensitivity to materials used in joint prostheses is relatively common but often unrecognized. Although the discussion applies to all joints, the temporomandibular joint (TMJ) is emphasized. For TMJ reconstruction, metal-on-polyethylene articulation in total joint prostheses provides better treatment outcomes than metal-on-metal articulation.

Life expectancy of modular Ti6Al4V hip implants: influence of stress and environment

Stress dependent electrochemical dissolution is identified as one of the key mechanisms governing surface degradation in fretting and crevice corrosion of biomedical implants. The present study focuses on delineating the roles of mechanical stress and chemical conditions on the life expectancy of modular hip implants. First, material removal on a stressed surface of Ti6Al4V subjected to single asperity contact is investigated experimentally to identify the influence of contact load, in-plane stress and chemical environment on mean wear rates. A range of known stress levels are applied to the specimen while its surface is mechanically stimulated in different non-reactive to oxidizing aqueous environments. Evolution of surface degradation is monitored, and its mechanism is elucidated. This phase allows estimation of Preston Constant which is later used in the analysis. Second phase of the work is semi-analytical and computational, where, based on the estimated Preston constant and other material and process parameters, the scratch propensity (consisting of magnitude of scratch depth and their frequency per unit area) due to micro-motion in modular hip implants is estimated. The third phase views these scratches as initial notches and utilizes a mixed-mode fatigue crack propagation model to estimate the critical crack length for onset of instability. The number of loading cycles needed to reach this critical crack length is then labeled as the expected life of the implant under given mechanical and chemical conditions. Implications of different material and process conditions to life expectancy of orthopedic implants are discussed. It is observed that transverse micro-motion, compared to longitudinal micro-motion, plays a far more critical role in determining the implant life. Patient body weight, as well as proximity of the joint fluid to its iso-electric point play key roles in determining wear rates and associated life expectancies of modular hip implants. Sustained aeration of joint fluid, as well as proper tolerancing of mating surfaces, along with a proper choice of material microstructure may be utilized to extend implant life.

Influence of material coupling and assembly condition on the magnitude of micromotion at the stem-neck interface of a modular hip endoprosthesis

Hip prostheses with a modular neck exhibit, compared to monobloc prostheses, an additional interface which bears the risk of fretting as well as corrosion. Failures at the neck adapter of modular prostheses have been observed for a number of different designs. It has been speculated that micromotions at the stem-neck interface were responsible for these implant failures. The purpose of this study was to investigate the influence of material combinations and assembly conditions on the magnitude of micromotions at the stem-neck interface during cyclic loading. Modular (n = 24) and monobloc (n = 3) hip prostheses of a similar design (Metha, Aesculap AG, Tuttlingen, Germany) were subjected to mechanical testing according to ISO 7206-4 (F(min) = 230N, F(max) = 2300N, f = 1Hz, n = 10,000 cycles). The neck adapters (Ti-6Al-4V or Co-Cr29-Mo alloy) were assembled with a clean or contaminated interface. The micromotion between stem and neck adapter was calculated at five reference points based on the measurements of the three eddy current sensors. The largest micromotions were observed at the lateral edge of the stem-neck taper connection, which is in accordance with the crack location of clinically failed prostheses. Titanium neck adapters showed significantly larger micromotions than cobalt-chromium neck adapters (p = 0.005). Contaminated interfaces also exhibited significantly larger micromotions (p < 0.001). Since excessive micromotions at the stem-neck interface might be involved in the process of implant failure, special care should be taken to clean the interface prior to assembly and titanium neck adapters with titanium stems should generally be used with caution.

Basic science considerations in primary total hip replacement arthroplasty

Total Hip Replacement is one of the most common operations performed in the developed world today. An increasingly ageing population means that the numbers of people undergoing this operation is set to rise. There are a numerous number of prosthesis on the market and it is often difficult to choose between them. It is therefore necessary to have a good understanding of the basic scientific principles in Total Hip Replacement and the evidence base underpinning them. This paper reviews the relevant anatomical and biomechanical principles in THA. It goes on to elaborate on the structural properties of materials used in modern implants and looks at the evidence base for different types of fixation including cemented and uncemented components. Modern bearing surfaces are discussed in addition to the scientific basis of various surface engineering modifications in THA prostheses. The basic science considerations in component alignment and abductor tension are also discussed. A brief discussion on modular and custom designs of THR is also included. This article reviews basic science concepts and the rationale underpinning the use of the femoral and acetabular component in total hip replacement.

Modular titanium alloy neck adapter failures in hip replacement--failure mode analysis and influence of implant material

BACKGROUND

Modular neck adapters for hip arthroplasty stems allow the surgeon to modify CCD angle, offset and femoral anteversion intraoperatively. Fretting or crevice corrosion may lead to failure of such a modular device due to high loads or surface contamination inside the modular coupling. Unfortunately we have experienced such a failure of implants and now report our clinical experience with the failures in order to advance orthopaedic material research and joint replacement surgery.The failed neck adapters were implanted between August 2004 and November 2006 a total of about 5000 devices. After this period, the titanium neck adapters were replaced by adapters out of cobalt-chromium. Until the end of 2008 in total 1.4% (n = 68) of the implanted titanium alloy neck adapters failed with an average time of 2.0 years (0.7 to 4.0 years) postoperatively. All, but one, patients were male, their average age being 57.4 years (36 to 75 years) and the average weight 102.3 kg (75 to 130 kg). The failures of neck adapters were divided into 66% with small CCD of 130 degrees and 60% with head lengths of L or larger. Assuming an average time to failure of 2.8 years, the cumulative failure rate was calculated with 2.4%.

METHODS

A series of adapter failures of titanium alloy modular neck adapters in combination with a titanium alloy modular short hip stem was investigated. For patients having received this particular implant combination risk factors were identified which were associated with the occurRence of implant failure. A Kaplan-Meier survival-failure-analysis was conducted. The retrieved implants were analysed using microscopic and chemical methods. Modes of failure were simulated in biomechanical tests. Comparative tests included modular neck adapters made of titanium alloy and cobalt chrome alloy material.

RESULTS

Retrieval examinations and biomechanical simulation revealed that primary micromotions initiated fretting within the modular tapered neck connection. A continuous abrasion and repassivation process with a subsequent cold welding at the titanium alloy modular interface. Surface layers of 10 - 30 microm titanium oxide were observed. Surface cracks caused by fretting or fretting corrosion finally lead to fatigue fracture of the titanium alloy modular neck adapters. Neck adapters made of cobalt chrome alloy show significantly reduced micromotions especially in case of contaminated cone connection. With a cobalt-chromium neck the micromotions can be reduced by a factor of 3 compared to the titanium neck. The incidence of fretting corrosion was also substantially lower with the cobalt-chromium neck configuration.

CONCLUSIONS

Failure of modular titanium alloy neck adapters can be initiated by surface micromotions due to surface contamination or highly loaded implant components. In the present study, the patients at risk were men with an average weight over 100 kg. Modular cobalt chrome neck adapters provide higher safety compared to titanium alloy material.

In vitro assessment of serum-saline ratios for fluid simulator testing of highly modular spinal implants with articulating surfaces

BACKGROUND

The increasing complexity of articulating spinal implants prohibits the use of serum-supplemented simulator fluid testing because multicomponent interfaces retain residual protein and preclude gravimetric measurement. Our original hypothesis was that simulator testing of a posterior dynamic stabilization implant that has metal-on-metal articulating bearings will not produce dramatically different wear debris when tested using pure saline versus testing in saline supplemented with 20% serum.

METHODS

This hypothesis was tested using simulator testing of 12 dynamic stabilization spinal implants, 6 in 100% saline and 6 in 20%-serum saline. Gravimetric and particle analysis were performed after every million cycles up to 10 million cycles, with flexion of 11.3°/extension of 5.6° coupled with axial rotation of ± 4°.

RESULTS

The mean gravimetric weight loss was approximately 200 mg over 10 million cycles for the implants tested in 100% saline, while the mean weight loss for those tested in 20%-serum saline was below the method detection limits (< 10 mg over 10 million cycles). For the 100%-saline and 20%-serum simulator fluids, the average particle size over the course of 0 to 10 million cycles remained relatively constant at 0.2 µm-dia (saline) and 3.2 µm-dia (20%-serum saline). Testing in 100% saline generated > 1000-fold more particles, compared to testing in 20% serum-supplemented saline. Energy-dispersive X-ray (EDAX) analyses of particles demonstrated that the 100% saline debris was composed of Co-Cr-P-O (Cr-Co metal oxides), and for the 20%-serum saline debris only bulk metal Co-Cr was detected.

CONCLUSION

Our initial hypothesis was not supported. There were significant differences in gravimetric wear, average size, and type of wear debris that were mechanistically attributable to the type of simulator fluid used. The over-protective effect of serum proteins appears to underscore the importance of using both saline and serum when establishing upper and lower bounds of predictive implant debris generation modeling, where saline represents a worst-case scenario and as little as 20% serum masks all weight loss completely in highly modular articulating implants.

CLINICAL RELEVANCE

Clinical Relevance = 5 (Oxford Centre for Evidence-based Medicine Levels of Evidence). Study findings are limited to a greater understanding of the science associated with predictive wear testing of articulating spinal implants.

Special modes of corrosion under physiological and simulated physiological conditions

The aim of this article is to review those aspects of corrosion behaviour that are most relevant to the clinical application of implant alloys. The special modes of corrosion encountered by implant alloys are presented. The resistance of the different materials against the most typical corrosion modes (pitting corrosion, crevice corrosion and fretting corrosion) is compared, together with observations of metal ion release from different biomaterials. A short section is dedicated to possible galvanic effects in cases when different types of materials are combined in a biomedical device. The different topics covered are introduced from the viewpoint of materials science, and then placed into the context of medicine and clinical experience.

Mechanical load-assisted dissolution of metallic implant surfaces: influence of contact loads and surface stress state

Mechanical load-assisted dissolution is identified as one of the key mechanisms governing material removal in fretting and crevice corrosion of biomedical implants. In the current study, material removal on a stressed surface of cobalt-chromium-molybdenum (CoCrMo) subjected to single asperity contact is investigated in order to identify the influence of contact loads and in-plane stress state on surface damage mechanisms. The tip of an atomic force microscope is used as a well-characterized "asperity" to apply controlled contact forces and mechanically stimulate the loaded specimen surface in different aqueous environments from passivating to corroding. The volume of the material removed is measured to determine the influence of contact loads, in-plane stresses and the environment on the material dissolution rate. Experimental results indicate that surface damage is initiated at all the contact loads studied and as expected in a wear situation, removal rate increases with increase in contact loads. Removal rates display a complex dependence on residual stresses and the environment. In a passivating environment, the material removal rate is linearly dependent on the stress state such that surface damage is accelerated under compressive stresses and suppressed under tensile stresses. In a corrosive environment, the dissolution rate demonstrates a quadratic dependence on stress, with both compressive and tensile stresses accelerating material dissolution. A surface damage mechanism based on stress-assisted dissolution is proposed to elucidate the experimental observations.

Catastrophic failure of 4 cobalt-alloy Omnifit hip arthroplasty femoral components

BACKGROUND

Femoral component neck fracture is an uncommon type of failure in total hip arthroplasty. We present a report on 4 retrieved cobalt-chrome femoral components that fractured at the neck, where we investigated the mechanisms of failure.

METHODS

The 4 retrieved implants were analyzed with regard to their macro- and microstructures and the fracture surfaces were examined using electron microscopy. The medical record of each patient was also examined for any history of complications prior to failure of the implant.

RESULTS

These fractures occurred immediately adjacent to the base of the modular head. Skirted modular heads were used in 3 of the 4 failed components. This constructs promotes corrosion. Cyclic fatigue-loading in combination with the material factors of course grain microstructure and extensive carbide precipitation along the grain boundaries were also identified as the cause of implant failure.

INTERPRETATION

Our findings suggest that a solution annealing step could be introduced into the manufacturing process to improve the microstructure of the cobalt chrome alloy. We also advise caution in using a skirted modular head in combination with a device of known suboptimum microstructure, for a greater margin of safety.

Complex revision total hip arthroplasty with modular stems at a mean of 14 years

We retrospectively reviewed 87 patients (92 hips) who had revision hip surgery to determine whether a proximally coated, modular femoral component would remain stably fixed at long-term followup. Thirteen patients died and 12 patients were lost to followup leaving 62 patients (67 hips) available for review with minimum followup of 8 years (mean, 14 years; range, 8-17 years). Preoperative radiographs were reviewed using Paprosky's classification. Postoperative radiographs were reviewed for osteolysis, endosteal hypertrophy, cortical hypertrophy, distal pedestals, component breakage, and loosening. Thirty-seven hips underwent femoral allografting, 10 of which were proximal femurs. With revision as the endpoint the Kaplan-Meier survivorship (including deaths and loss to followup) was 60% at 14 years. Forty-seven of the 57 (82%) noncemented stems were bone ingrown. All had relative proximal bone preservation and 33 of 57 (58%) had bone hypertrophy in the diaphysis around zones 2 and 6. There were five aseptic failures (9%). Each of those was Paprosky Class IIIB or IV preoperatively. There were no long-term failures in Paprosky Class II or IIIA. The aseptic failures have been re-revised. This modular stem resulted in reliable fixation with relative preservation of proximal bone stock at this intermediate interval in complex revisions in Paprosky Class II and IIIA. Paprosky Class IIIB and IV defects may need additional component fixation options.

Anodized titanium and stainless steel in contact with CFRP: An electrochemical approach considering galvanic corrosion

The combination of different materials in an implant gives the opportunity to better fulfill the requirements that are needed to improve the healing process. However, using different materials increases the risk of galvanic coupling corrosion. In this study, coupling effects of gold-anodized titanium, stainless steel for biomedical applications, carbon fiber reinforced polyetheretherketone (CFRP), and CFRP containing tantalum fibers are investigated electrochemically and by long-term immersion experiments in simulated body fluid (SBF). Potentiodynamic polarization experiments (i/E curves) and electrochemical impedance spectroscopy (EIS) of the separated materials showed a passive behavior of the metallic samples. Anodized titanium showed no corrosion attacks, whereas stainless steel is highly susceptibility for localized corrosion. On the other side, an active dissolution behavior of both of the CFRPs in the given environment could be determined, leading to delaminating of the carbon fibers from the matrix. Long-term immersion experiments were carried out using a set-up especially developed to simulate coupling conditions of a point contact fixator system (PC-Fix) in a biological environment. Electrochemical data were acquired in situ during the whole immersion time. The results of the immersion experiments correlate with the findings of the electrochemical investigation. Localized corrosion attacks were found on stainless steel, whereas anodized titanium showed no corrosion attacks. No significant differences between the two CFRP types could be found. Galvanic coupling corrosion in combination with crevice conditions and possible corrosion mechanisms are discussed.

Trunion fracture of a fully porous-coated femoral stem. Case report

Femoral component fracture is a documented but an uncommon complication of total hip arthroplasty. A retrospective survey conducted by the American Association of Hip and Knee Surgeons estimated the prevalence of femoral component fractures at 0.27% (172 of 64483 implants over a 5-year period ending in 1993) . There have been several case reports of fatigue fractures of the prosthetic neck distal to the Morse taper in modular implants with a cobalt alloy head and a cobalt alloy stem. Here, we present a case report of stem fracture within the Morse taper of a cobalt alloy stem coupled with a cobalt alloy head.

Simulation of Fretting Wear at Orthopaedic Implant Interfaces

Osteolysis due to wear debris is a primary cause of failure of total joint replacements. Although debris produced by the joint articulating surfaces has been studied and simulated extensively, fretting wear debris, produced at nonarticulating surfaces, has not received adequate attention. We developed a three-station fretting wear simulator to reproduce in vivo motion and stresses at the interfaces of total joint replacements. The simulator is based on the beam bending theory and is capable of producing cyclic displacement from 3to1000microns, under varying magnitudes of contact stresses. The simulator offers three potential advantages over previous studies: The ability to control the displacement by load, the ability to produce very small displacements, and dynamic normal loads as opposed to static. A pilot study was designed to test the functionality of the simulator, and verify that calculated displacements and loads produced the predicted differences between two commonly used porous ingrowth titanium alloy surfaces fretting against cortical bone. After 1.5 million cycles, the simulator functioned as designed, producing greater wear of bone against the rougher plasma-sprayed surface compared to the fiber-mesh surface, as predicted. A novel pin-on-disk apparatus for simulating fretting wear at orthopaedic implant interfaces due to micromotion is introduced. The test parameters measured with the fretting wear simulator were as predicted by design calculations, and were sufficient to measure differences in the height and weight of cortical bone pins rubbing against two porous ingrowth surfaces, plasma-sprayed titanium and titanium fiber mesh.

In vitro corrosion testing of modular hip tapers

The in vivo fretting behavior of modular hip prostheses was simulated to determine the effects of material combination and a unique TiN/AlN coating on fretting and corrosion at the taper interface. Fretting current, open-circuit potential (OCP), and quantities of soluble debris were measured to determine the role of mechanically assisted crevice corrosion on fretting and corrosion of modular hip tapers. Test groups consisting of similar-alloy (Co-Cr-Mo head/Co-Cr-Mo neck), mixed-alloy (Co-Cr-Mo head/Ti-6Al-4V neck), and TiN/AlN-coated mixed-alloy modular hip taper couples were used. Loads required to initiate fretting were similar for all test groups and were well below loads produced by walking and other physical activities. Decreases in OCP and increases in fretting current observed during long-term cyclic loading were indicative of fretting and corrosion. Current measured after cessation of cyclic loading suggests that once the conditions for crevice corrosion are established, corrosion can continue in the absence of loading. The chemical, mechanical, and electrochemical measurements, along with microscopic inspections of the taper surfaces indicate that the fretting and corrosion behavior of similar- and mixed-alloy taper couples are similar and that the coated samples are more resistant to fretting and corrosion. The results of this study clearly indicate the role of mechanical loading in the corrosion process, and support the hypothesis of mechanically assisted crevice corrosion.

Serum levels of cobalt and chromium in a complex modular total hip arthroplasty system

There is concern that modularity in a total hip arthroplasty system increases serum cobalt and chromium ion levels. This study measures the serum cobalt and chromium levels in patients with an Oxford Universal Hip (Corin, Cirencester, United Kingdom), which has a modular sliding mechanism; patients with a similarly manufactured hip with no sliding mechanism; and a control group. Loosening was excluded clinically and radiologically. Arthroplasty patients had statistically higher levels of serum cobalt and chromium than controls, but there was no significant difference in levels between the implanted groups.

A multicenter retrieval study of the taper interfaces of modular hip prostheses

A multicenter retrieval analysis of 231 modular hip implants was done to investigate the effects of material combination, metallurgic condition, flexural rigidity, head and neck moment arm, neck length, and implantation time on corrosion and fretting of modular taper surfaces. Scores for corrosion and fretting were assigned to medial, lateral, anterior, and posterior quadrants of the necks, and proximal and distal regions of the heads. Neck and head corrosion and fretting scores were found to be significantly higher for mixed alloy versus similar alloy couples. Moderate to severe corrosion was observed in 28% of the heads of similar alloy couples and 42% of the heads of mixed alloy couples. Differences in corrosion scores were observed between components made from the same base alloy, but of different metallurgic conditions. Corrosion and fretting scores tended to be higher for heads than necks. Implantation time and flexural rigidity of the neck were predictors of head and neck corrosion and head fretting. The results of this study suggest that in vivo corrosion of modular hip taper interfaces is attributable to a mechanically-assisted crevice corrosion process. Larger diameter necks will increase neck stiffness and may reduce fretting and subsequent corrosion of the taper interface regardless of the alloy used. Increasing neck diameter must be balanced, however, with the resulting loss of range of motion and joint stability.

Metal release in patients who have had a primary total hip arthroplasty. A prospective, controlled, longitudinal study

There is an increasing recognition that, in the long term, total joint replacement may be associated with adverse local and remote tissue responses that are mediated by the degradation products of prosthetic materials. Particular interest has centered on the metal-degradation products of total joint replacements because of the known toxicities of the metal elements that make up the alloys used in the implants. We measured the concentrations of titanium, aluminum, cobalt, and chromium in the serum and the concentration of chromium in the urine of seventy-five patients during a three-year prospective, longitudinal study. Twenty patients had had a so-called hybrid total hip replacement (insertion of a modular cobalt-alloy femoral stem and head with cement and a titanium acetabular cup without cement), fifteen had had insertion of an extensively porous-coated cobalt-alloy stem with a cobalt-alloy head and a titanium-alloy socket without cement, and twenty had had insertion of a proximally porous-coated titanium-alloy stem with a cobalt-alloy head and a titanium socket without cement. The remaining twenty patients did not have an implant and served as controls. The results of our study showed that, thirty-six months postoperatively, patients who have a well functioning prosthesis with components containing titanium have as much as a threefold increase in the concentration of titanium in the serum and those who have a well functioning prosthesis with cobalt-alloy components have as much as a fivefold and an eightfold increase in the concentrations of chromium in the serum and urine, respectively. The predominant source of the disseminated chromium-degradation products is probably the modular head-neck junction and may be a function of the geometry of the coupling. Passive dissolution of extensively porous-coated cobalt-alloy stems was not found to be a dominant mode of metal release.

CLINICAL RELEVANCE

Increased concentrations of circulating metal-degradation products derived from orthopaedic implants may have deleterious biological effects over the long term that warrant investigation. This is a particularly timely concern because of recent clinical trends, including the reintroduction of metal-on-metal bearing surfaces and the increasing popularity of extensively porous-coated devices with large surface areas of exposed metal. Accurate monitoring of the concentrations of metal in the serum and urine after total hip replacement also can provide insights into the mechanisms of metal release. Our findings suggest that fretting corrosion at the head-neck coupling is an important source of metal release that can lead to increased concentrations of chromium in the serum. Determinations of the concentrations of metal in the serum and urine may be useful in the diagnosis of patients who are symptomatic after a total joint replacement as increased levels are indicative of at least one mode of mechanical dysfunction (for example, fretting corrosion) of the device.

Evaluation of fibrocartilage regeneration and bone response at full-thickness cartilage defects in articulation with pyrolytic carbon or cobalt-chromium alloy hemiarthroplasties

Hemiarthroplasty is one method used to treat osteoarthritic joints. Often, however, an adverse response of the articular cartilage to the metal implants occurs. The purpose of this study was to evaluate and compare the response of a surgically created defect to pyrolytic carbon and cobalt-based alloy hemiarthroplasties. The cartilage on the lateral side of the tibial plateau of a canine knee joint was abraded to create a full-thickness defect. Two small holes were drilled into the exposed subchondral bone. Next, either a carbon or metal implant was placed in the lateral femoral condyle. The implantation period was 1 year. Histologic examination of the tibial defects revealed a smooth bony surface for both implant groups. In addition, there was no evidence of a residual adverse inflammatory response nor of a significant increase in subchondral bone formation for either group. Surface cracks resulting from the presence of the implant were seen in 14% of the carbon implant specimens and in 100% of the metal implants. Fibrocartilage regeneration was seen in 86% of the carbon implants and in 25% of the metal implants. Thus the carbon appears to be better tolerated mechanically compared to wrought cobalt-chromium alloy. Pyrolytic carbon shows promise for use in hemiarthroplasty.

Distribution of cobalt chromium wear and corrosion products and biologic reactions

Replacement hip arthroplasty with the use of ultrahigh molecular weight polyethylene for the cup articulating with a metal head has provided a low friction arthroplasty with years of success. However, the search for improved materials and designs for articulating surfaces continues. The use of metallic heads articulating with metallic cups is now being reconsidered for total hip replacements. Success will be enhanced if wear and corrosion of the articulating surfaces can be kept below that of the metal on ultrahigh molecular weight polyethylene couple. Concern has been raised about the release, and biologic fate, of metal species from corrosion and wear. Titanium alloys have been shown to have limitations as an articulating surface showing significant wear, and the alloy per se should not be considered for wear couples in total hip replacements. The cobalt chromium alloys are known to have reasonable wear and corrosion properties and continue to be evaluated. The issue of cobalt chromium wear and corrosion products and how this relates to the biologic performance of total hip replacement devices is reviewed. Under the condition of wear as currently experienced at the articulating surfaces of cobalt chromium alloys and ultrahigh molecular weight polyethylene, the amount of metallic products transferred to the tissues is sufficiently low to be well tolerated by the biologic system. Nickel and cobalt ions arc, rapidly transported from the implant site and eliminated in the urine. Chromium is stored in the tissue and eliminated more slowly. The issue of host hypersensitivity to these elements remains of concern. All 3 elements, in ionic form, are known to cause contact dermatitis. Untoward biologic reactions, including hypersensitivity, should be minimized if wear and corrosion phenomena are minimized.