Clinical and simulator wear study of alumina ceramic THR to 17 years and beyond

Liner type has no impact on bone mineral density changes around a 3D printed trabecular titanium acetabular component

BACKGROUND

Three-dimensional printing of implants allows the ability to produce implants and interfaces which theoretically better mimic "normal" bone behaviour, leading to a possible reduction in stress shielding thus maintaining bone mineral density (BMD). This issue was not investigated in vivo using bone scan and different bearings; therefore, we did a prospective study aiming to answer: 1) is there a loss of BMD around the 3D printed trabecular titanium cup, when compared to the native hip?; 2) does liner type influence the BMD changes around the acetabulum when a 3D printed trabecular titanium cup is used?

HYPOTHESIS

BMD changes around the acetabulum are not influenced by the liner type, and the cup will be associated with a reduction in BMD when compared to the native hip.

MATERIAL AND METHODS

This is a prospective observational study of patients receiving a primary total hip arthroplasty. A 3D printed trabecular titanium uncemented acetabular component was used in all cases. All patients received a ceramic femoral head, with either a ceramic or polyethylene acetabular liner. BMD measurements using DXA were performed at 6 weeks, 6, 12 and 24 months after surgery to evaluate remodeling changes. The 3 acetabular regions of interest (ROI) of DeLee and Charnley were used for serial comparisons of peri-acetabular BMD. The study was powered as a non-inferiority study with the principle variables compared using a two-step repeated analysis of variance.

RESULTS

A total of 48 consecutive patients were included in the study, with all patients completing their 2 year follow-up. There were no failures, revisions or complications within this cohort. We found no statistically significant difference in the BMD change scores between the operated and the native hip in any of the 3 ROI zones. We found no differences in BMD scores when comparing ceramic to polyethylene acetabular liners, head sizes and BMI.

DISCUSSION

This study shows a similar pattern of BMD behaviour around a 3D printed cup when compared to the contralateral native hip. We were unable to show a clinical or radiological difference between the bearing material, head size, or BMI when used with this type of acetabular component.

LEVEL OF EVIDENCE

III; prospective comparative study.

Noise characteristics in ceramic-on-ceramic vs. metal-on-polyethylene total hip arthroplasty: a comparative study

INTRODUCTION

A comparison of noise in ceramic-on-ceramic (CoC) bearings and metal-on-polyethylene (MoP) bearings after total hip arthroplasty (THA) was undertaken. Noise associated with MoP implants is rarely reported and has not been linked to squeaking.

METHODS

A noise characterising hip questionnaire and Oxford Hip Score (OHS) was sent to 1,000 THA patients; there were 509 respondents 282 CoC and 227 MoP; mean age 63.7 years (range 45-92 years), mean follow up 33 months (range 6-156 months).

RESULTS

Of 282 repsondents 47 (17%) of the CoC patients reported noise compared to 19 (8%) of the MoP patients (p = 0.048); 9 CoC patients and 4 MoP patients reported squeaking. Overall, 27% patients with noise reported avoiding recreational activities because of it and patients with noisy hips scored on average 5 points less on the OHS (CoC: p = 0.04 and MoP: p = 0.007).

DISCUSSION

This is the first study to report squeaking from MoP THAs. The squeaking hip phenomenon is not exclusive to CoC THAs. Noisy hip implants may have social implications, and patients should be aware of this. We have shown a relationship between noise and a lower OHS. However, longer follow-up is needed to link noise to a poorly functioning implant.

May the surface roughness of the retrieved femoral head influence the wear behavior of the polyethylene liner?

This study was aimed at determining the surface degradation occurred on retrieved ceramic and metallic heads, as well as the influence of the head surface quality on the wear of the polyethylene counterface. To this purpose, 14 ceramic and 14 metallic femoral heads retrieved at revision surgery were examined. Scanning electron microscopic analysis provided visual evidence that some metallic heads presented crescent wear more often than the ceramic ones; the former showed a higher volumetric loss (as determined by Coordinate Measuring Machine) than the latter, but less negative Rsk values. This apparent lack of correlation between volumetric loss (i.e., wear factor) and roughness data may be explained by considering that they are two temporally variant parameters. No significant differences were observed between the Ra values of the two sets of femoral heads. The cups articulating against metal heads were characterized by higher mean wear volumes than those articulating against alumina although this difference was not statistically significant; metal heads displayed significantly higher mean wear volumes than alumina heads. The micro-Raman analysis of the cup articulated against the most worn alumina femoral head showed an orthorhombic into monoclinic phase transformation that was not observed in the cups coupled to metal heads. The obtained results showed that the surface finishing of the femoral head (in terms of Rsk values) determined the morphological changes experienced by the ultra-high-molecular-weight polyethylene crystalline phase at the molecular level. © 2015 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 104B: 1374-1385, 2016.

Bioceramics for Hip Joints: The Physical Chemistry Viewpoint

Which intrinsic biomaterial parameter governs and, if quantitatively monitored, could reveal to us the actual lifetime potential of advanced hip joint bearing materials? An answer to this crucial question is searched for in this paper, which identifies ceramic bearings as the most innovative biomaterials in hip arthroplasty. It is shown that, if in vivo exposures comparable to human lifetimes are actually searched for, then fundamental issues should lie in the physical chemistry aspects of biomaterial surfaces. Besides searching for improvements in the phenomenological response of biomaterials to engineering protocols, hip joint components should also be designed to satisfy precise stability requirements in the stoichiometric behavior of their surfaces when exposed to extreme chemical and micromechanical conditions. New spectroscopic protocols have enabled us to visualize surface stoichiometry at the molecular scale, which is shown to be the key for assessing bioceramics with elongated lifetimes with respect to the primitive alumina biomaterials used in the past.

Risk of impingement and third-body abrasion with 28-mm metal-on-metal bearings

BACKGROUND

Concerns have been raised about the sequelae of metal-on-metal (MoM) bearings in total hip arthroplasty (THA). However, retrieval studies, which offer the best insight into the clinically relevant mechanisms of MoM wear, have followed predictable trends to date such as indicting cobalt-chromium (CoCr) metallurgy, cup design, high conformity between the head and cup, "steep cups," "microseparation," and "edge wear."

QUESTIONS/PURPOSES

We wished to evaluate a set of retrieved 28-mm MoM THA for signs of (1) cup-to-stem impingement; (2) normal wear pattern and concomitant stripe damage on femoral heads that would signify adverse wear mechanics; and (3) well-defined evidence of third-body scratches on bearings that would indicate large abrasive particles had circulated the joint space.

METHODS

Ten 28-mm MOM retrievals were selected on the basis that femoral stems were included. Revision surgeries at 3 to 8 years were for pain, osteolysis, and cup loosening. CoCr stems and the MoM bearings were produced by one vendor and Ti6Al4V stems by a second vendor. All but two cases had been fixed with bone cement. We looked for patterns of normal wear and impingement signs on femoral necks and cup rims. We looked for adverse wear defined as stripe damage that was visually apparent on each bearing. Wear patterns were examined microscopically to determine the nature of abrasions and signs of metal transfer. Graphical models recreated femoral neck and cup designs to precisely correlate impingement sites on femoral necks to cup positions and head stripe patterns.

RESULTS

The evidence revealed that all CoCr cup liners had impinged on either anterior or posterior facets of femoral necks. Liner impingement at the most proximal neck notch occurred with the head well located and impingement at the distal notch occurred with the head rotated 5 mm out of the cup. The hip gained 20° motion by such a subluxation maneuver with this THA design. All heads had stripe wear, the basal and polar stripes coinciding with cup impingement sites. Analysis of stripe damage revealed 40 to 100-μm wide scratches created by large particles ploughing across bearing surfaces. The association of stripe wear with evidence of neck notching implicated impingement as the root cause, the outcome being the aggressive third-body wear.

CONCLUSIONS

We found consistent evidence of impingement, abnormal stripe damage, and evidence of third-body abrasive wear in a small sample of one type of 28-mm MoM design. Impingement models demonstrated that 28-mm heads could lever 20° out of the liners. Although other studies continue to show good success with 28-mm MoM bearings, their use has been discontinued at La Pitie Hospital.

Stress microscopy and confocal Raman imaging of load-bearing surfaces in artificial hip joints

Confocal Raman microprobe spectroscopy is a technique with considerable potential in biomedical science owing to its ability to nondestructively scan samples in 3D with high spatial resolution and to precisely characterize the chemical, physical and mechanical characteristics of biomaterials at their molecular scale. Beyond the capacity of other conventional assessments of biomaterial oxidation state, crystalline and phase fractions, Raman and luminescence techniques can be used for assessing residual stress fields in artificial hip joints. Provided that the probe response function characterizing the probe/biomaterial interaction is known, 3D residual stress fields can be determined precisely with high axial and lateral resolution.

The effect of lubrication on the friction and wear of Biolox®delta

The performance of total hip-joint replacements depends strongly on the state of lubrication in vivo. In order to test candidate prosthetic materials, in vitro wear testing requires a lubricant that behaves in the same manner as synovial fluid. The current study investigated three lubricants and looked in detail at the lubrication conditions and the consequent effect on ball-on-flat reciprocating wear mechanisms of Biolox®delta against alumina. Biolox®delta, the latest commercial material for artificial hip-joint replacements, is an alumina-matrix composite with improved mechanical properties through the addition of zirconia and other mixed oxides. Three commonly used laboratory lubricants, ultra pure water, 25 vol.% new-born calf serum solution and 1 wt.% carboxymethyl cellulose sodium salt (CMC-Na) solution, were used for the investigation. The lubrication regimes were defined by constructing Stribeck curves. Full fluid-film lubrication was observed for the serum solution whereas full fluid-film and mixed lubrications were observed in both water and the CMC-Na solution. The wear rates in the CMC-Na and new-born calf serum were similar, but were an order of magnitude higher in water. The worn surfaces all exhibited pitting, which is consistent with the transition from mild wear to severe or "stripe" wear. The extent of pitting was greatest in the serum solution, but least in the water. On all worn surfaces, the zirconia appeared to have fully transformed from tetragonal to monoclinic symmetry. However, there was no evidence of microcracking associated with the transformed zirconia. Nevertheless, AFM indicated that zirconia was lost preferentially to the alumina grains during sliding. Thus, the current study has shown conclusively that the wear mechanisms for Biolox®delta clearly depend on the lubricant used, even where wear rates were similar.

Effect of protein concentrations of bovine serum albumin and γ-globulin on the frictional response of a cobalt-chromium femoral head

The study aims to identify the concentration-dependent role of bovine serum albumin (BSA) and γ-globulin in the lubricating ability of a cobalt-chromium femoral head. The frictional coefficients of the cobalt-chromium femoral head decreased with increasing BSA concentrations from 10 to 40 mg/ml and showed statistical differences between any of the BSA concentration groups, except between the 30 and 40 mg/ml concentration groups. In γ-globulin, the frictional coefficients significantly decreased at concentrations of 2.5 and 5.0 mg/ml as compared with the PBS control group, but significant increases were observed at 7.5 and 12.5 mg/ml. These results suggest that the friction of the cobalt-chromium femoral head is dependent on the concentration of both BSA and γ-globulin. However, there is a maximum concentration for BSA to act as an effective boundary lubricant, while the lubricating ability of γ-globulin is most effective in the physiological concentration range within human synovial fluid.

Squeaking in third- and fourth-generation ceramic-on-ceramic total hip arthroplasty: meta-analysis and systematic review

Postoperative squeaking in ceramic-on-ceramic total hip arthroplasty is a recently emerging phenomenon. We performed a meta-analysis of published data to examine patient and procedural risk factors. Twelve studies (6137 patients, total) were analyzed, with 150 patients (2.4%) complaining of squeaking. The only significant patient risk factor was increasing body mass index (P = .03, n = 2957). There was no significance found with patient age, sex, height, weight, or procedural laterality for squeak incidence. For implant type, the presence of a Stryker Accolade femoral stem (beta-titanium; Stryker Orthopedics, Mahwah, NJ) was significantly found to increase squeak (P < .0001, n = 4654). The presence of a raised metallic lip on the acetabular component was not found to be associated with squeak. Acetabular cup position was also not found to have a significant bearing on the incidence of squeaking.

Wear degradation of long-term in vivo exposed alumina-on-alumina hip joints: linking nanometer-scale phenomena to macroscopic joint design

The wear behavior of alumina femoral heads was examined at follow-up periods between 7.7 and 10.7 years. Four head retrievals of the same size (28 mm in diameter) were divided into two groups with different design characteristics. Systematically using scanning electron and atomic force microscopy procedures, wear characteristics could be classified on the entire heads according to five zones with increasing degrees of wear damage (Grade 1-5), in addition to one zone of stripe wear (Grade SW). The stripe wear zone showed quite different topographical features as compared to frictionally worn zones. Furthermore, hip implants designed with different clearances are shown to lead to different wear patterns on the femoral head surface, the smaller the clearance the wider the worn surface area. Cathodoluminescence piezo-spectroscopy provided information about the residual stress state in surfaces worn to different degrees and helped clarifying the wear mechanisms on the microscopic scale.

Alumina-on-alumina hip implants

Alumina–alumina bearings are among the most resistant to wear in total hip replacement. Examination of their surfaces is one way of comparing damage caused by wear of hip joints simulated in vitro to that seen in explanted bearings. The aim of this study was to determine whether second-generation ceramic bearings exhibited a better pattern of wear than those reported in the literature for first-generation bearings. We considered both macro- and microscopic findings.

We found that long-term alumina wear in association with a loose acetabular component could be categorised into three groups. Of 20 specimens, four had ‘low wear’, eight ‘crescent wear’ and eight ‘severe wear’, which was characterised by a change in the physical shape of the bearing and a loss of volume. This suggests that the wear in alumina–alumina bearings in association with a loose acetabular component may be variable in pattern, and may explain, in part, why the wear of a ceramic head in vivo may be greater than that seen after in vitro testing.

Medium-term analysis of modern ceramic-on-ceramic bearing in THA

A variety of different bearing surfaces have been used to avoid osteolysis following hip replacement. We report a retrospective review of medium-term results of a modern ceramic-ceramic bearing (Biolox, CeramTec, Plochingen, Germany) and uncemented components (Alpha Cera Fit Alphanorm, Lassnitzhohe, Austria) in 107 hip arthroplasties. The clinical outcome based on serial radiographs and scoring was assessed with a minimum follow-up of 7 years (mean, 7, 6 years; range, 7, 1-8, 3 years). The average age of the patients at surgery was 64, 6 + 11, 7 years (range: 21-88 years). The mean Harris hip score was 90, 4 (range, 84, 7-99, 2). Three patients with an extra long femoral neck experienced fracture of the ceramic femoral head, resulting in cessation of use of this combination. Radiological evaluation did not reveal any signs of lysis or loosening. Massive heterotopic ossification was seen in three patients. Medium-term follow-up showed excellent clinical and radiological results. Continued follow-up will be required to determine if this ceramic-on-ceramic bearing is associated with extended survivorship.

How do alternative bearing surfaces influence wear behavior?

Metal, ceramic, and polyethylene liners represent contemporary bearing choices for total joint replacement. Each has limitations in terms of design, sensitivity to manufacturing, and surgical placement. With polyethylene, larger femoral heads represent a design restriction and a potential wear issue. One side benefit is that polyethylene does not click, squeak, or create stripe wear. The attraction of hard-on-hard bearings (metal-on-metal, ceramic-on-ceramic) is that their typically ultra-low wear alleviates concerns with large femoral head designs. However, hard-on-hard bearings produce stripe wear due to the effects of the rigid liner edge. Slight subluxation (microseparation) during swing phase of gait can result in stripe wear on the ball and liner rim. In addition, high levels of implant wear with vertically placed cups can be anticipated. Currently, only alumina-on-alumina bearings can claim virtually no biologic risk. Thus, the role of laboratory studies is to isolate relevant aspects of performance by cup design and to predict the risk-benefit ratios in patients requiring total hip replacement.

The role of stripe wear in causing acoustic emissions from alumina ceramic-on-ceramic bearings

Noise from ceramic-on-ceramic hip bearings has been reported during specific patient activities. Wear stripes, which have been seen in some clinical retrievals, may be associated with bearing noise. We produced wear stripes on ceramic bearings in the laboratory and determined that, under certain conditions, noise could occur during either edge loading or joint simulation. Squeaking was not observed with bearings in their pristine condition. We concluded that wear stripes caused by edge loading may be associated with bearing noise, during either edge loading alone or during normal articulation.

Three-dimensional laser micrometry characterization of surface wear in total hip arthroplasty

Even after decades of clinical use, our ability to quantify wear across total hip replacement implant surfaces is largely limited to single value measurements. The influence of patient factors on wear remains enigmatic. This pilot study for the development of three-dimensional laser micrometry (3DLM) introduces an easy, accurate means of 'mapping' and quantifying material removal. A three-dimensional laser micrometer was constructed using a laser micrometer having an accuracy of 0.5 microm. A 3D surface map is triangulated from a point cloud consisting of approximately 140,000 individual points. Comparison to a reference sphere determines radial wear over the entire surface. 3DLM was able to map and quantify fine scale surface features. Even for zirconia on relatively soft ultra-high molecular weight polyethylene, this technique maps the contributions of localized wear at the macroscopic level. The 0.5 microm (or greater) accuracy of these lasers allows us to image surfaces with a high degree of confidence. This analysis lends itself well to automation, and we anticipate that this advance will prove valuable in establishing that each head and cup combination emerging from a given clinical environment has unique wear patterns as observed in this trial data set.

Surface micro-analyses of long-term worn retrieved “Osteal™” alumina ceramic total hip replacement

We analyzed wear pattern of long-term retrieved alumina-alumina hip prostheses from Osteal, which were implanted for 15-19 years. A comparison was carried out with our previous study of 17-year Biolox alumina-on-alumina hip prostheses, (Shishido et al., J Biomed Mater Res B 2003;67:638-647) and all-alumina total hip replacement run under microseparation simulator tests. Of particular interest was the occurrence of stripe wear in these first generation alumina ceramic bearings. Two balls of Osteal revealed only one stripe wear as did the respective liners on their rim areas. In these latter balls, the stripes were shallower than those previously observed in Biolox implants. A microscopic analysis of the bearing surface was carried out using scanning electron microscopy and fluorescence microprobe spectroscopy. On average, the Osteal retrievals had one grade lower wear than Biolox retrievals. Fluorescence microprobe maps showed that Biolox ball surfaces had higher compressive stress than the Osteal likely due to severe impingement and microseparation promoted by the bulky implant design.

No increased migration in cups with ceramic-on-ceramic bearing: an RSA study

Ceramic-on-ceramic hip replacements might stress the bone interface more than a metal-polyethylene because of material stiffness, microseparation, and sensitivity to impingement. To ascertain whether this potentially increased stress caused an increased cup migration we compared a ceramic-on-ceramic with a metal-on-polyethylene implant for cup migration. Sixty one patients (61 hips) undergoing THA for osteoarthritis were randomized to ceramic on ceramic (Ce/Ce) or cobalt-chromium on cross-linked polyethylene bearings (PE) in the same uncemented cup shell. Migration was followed with RSA. At 2 years we observed similar mean cup translations in the 3 directions (0.07-0.40 mm vs. 0.05-0.31 mm, Ce/Ce vs. PE), as well as similar rotations around the 3 axes (0.31-0.92 degrees vs. 0.57-1.40 degrees). WOMAC and SF-36 scores were also similar and no radiolucent lines or osteolysis found. The large migration seen in some cups in both implant groups will require close monitoring to ascertain the reasons. Mean proximal wear of the polyethylene liners measured 0.016 mm between 2 and 24 months. Our data suggest there is no increased cup migration in the ceramic-on-ceramic implant compared with the metal-on-polyethylene, and they seem an equally safe choice. However, the low wear measured with the more versatile and less expensive cross-linked polyethylene makes it a strong contender.

LEVELS OF EVIDENCE

Therapeutic Level I. See the Guidelines for Authors for a complete description of levels of evidence.

Confocal Raman Spectroscopic Analysis of Ceramic Hip Joints

A survey of confocal Raman/fluorescence microprobe spectroscopic techniques is presented with emphasis placed on surface analysis of artificial hip joints. Suitable instrumental configurations are first explained in some details in order to describe the versatility of the spectroscopic microprobes to biomedical materials analyses. Then, these notions, which represent the foundation for structural and mechanical analyses of joint surfaces, are applied to selected cases of paramount importance in hip arthroplasty.

Fluorescence spectroscopic analysis of surface and subsurface residual stress fields in alumina hip joints

We aim to establish a confocal spectroscopic technique able to study the features of fluorescence spectra arising from native Cr3+ impurity in polycrystalline alumina (Al2O3) as a biomaterial and to use their emission lines as microscopic probes for the characterization of residual stress fields stored in artificial hip prostheses during their implantation in vivo. As an application of the technique, we report for the first time concerning the evolution of microscopic (residual) stress fields stored on the surface and in the subsurface of N=7 retrieved Al2O3 hip joints after exposure in the human body from a few months to 19 yr. The micrometric diameter of the laser beam waist impinging on the joint surface (typically about 1 microm in lateral resolution) enables us to estimate the patterns and magnitude of residual stress with high spatial resolution, at least comparable with the grain size of the material. In addition, a selected confocal configuration for the optical probe enables minimization of the probe size along the in-depth direction. According to a statistical collection of data on the microscopic level for retrieved femoral heads in toto, a residual stress field arising from loading history in vivo during the lifetime of the Al2O3 femoral head can be revealed. Finally, an interpretation is given of microscopic wear mechanisms in Al2O3 artificial hip joints consistent with the observed evolution of surface residual stress fields on elapsed time in vivo.

Current concepts of metal-on-metal hip resurfacing

The second-generation, metal-on-metal (MOM) bearing for total hip replacements was launched in the 1980s, and resurfacing followed in the mid-1990s. Remaining challenges include long-term bone remodeling of the femoral resurfacing and consideration of adverse MOM wear conditions. Precise understanding of manufacturing variables such as alloy types, bearing diameters, design tolerances, and surface finish is imperative in obtaining clinical consistency and safety in the patient. This review examines femoral fixation, bone remodeling, and wear studies of MOM implants and provides a brief overview of the latest outcome and retrieval data and how these data integrate with the in vitro wear studies.

Concerns about ceramics in THA

Currently available ceramic materials are superior to those used originally in total hip arthroplasty, which should translate into a much lower complication rate than what has been reported previously. In spite of this, a number of concerns remain. The ceramic-on-ceramic articulation is not immune to wear and surface damage. Conditions associated with ceramic wear include vertical cup position, femoral neck impingement, and femoral head separation. A unique pattern of stripe wear has been described as something that results from microseparation during gait. Catastrophic failure, although rare, continues to be a concern, and not all fractures can be predicted by proof testing. Revisions needed because of ceramic fractures can be extensive, and the results of the revision procedures can be compromised by the presence of highly abrasive particulate debris that is retained. Other concerns include the generation of debris from modular interfaces, neck damage and debris generation from impingement of some designs, inability to use a ceramic head a second time on a metal trunnion, and the dramatic loss of head and liner options intraoperatively. Although ceramics show great promise as a lower wear articulation, manufacturing and design modifications and improvements will continue in an attempt to address the substantial concerns that persist.

Stripe wear rates in alumina THR?Comparison of microseparation simulator study with retrieved implants

Alumina-on-alumina hip implants with microseparation were run in a hip simulator for comparison of the nonseparation simulator mode and retrievals. The 28-, 32-, and 36-mm Biolox-forte implants were run to 5 million cycles with the use of 50% newborn calf serum. Howmedica Osteonics Trident cups with titanium backing were used in all sets. In standard (STD) and microseparation (MSX) mode, the typical biphasic wear trend was evident, but the MSX test mode had much higher magnitudes. There was a 5-fold increase for run-in wear and up to a 35-fold increase in steady-state wear. The stripe wear on the ball formed early, but did not progress in grade beyond 0.6 Mc. The locations of the stripes were similar in retrieved and simulator balls. However, the stripes from the simulator were narrower than short-term retrievals and much narrower than some long-term retrievals. The long-term retrieved balls had a grade of wear greater than the simulators. In vivo a broader range of motion occurs and this may lead to the wider stripe observed on the retrievals. These observations suggested that simulators could produce the loading and kinematics similar to a patient walking but not necessarily the variety of motions possible in the in vivo situation.