In vitro measurement of interface micromotion and crack in cemented total hip arthroplasty systems with different surface roughness

Pre-clinical evaluation of fretting-corrosion at stem-head and stem-cement interfaces of hip implants using in vitro and in silico models

Prior to clinical use, the corrosion resistance of new prosthesis system must be verified. The fretting-corrosion mechanisms of total hip arthroplasty (THA) implants generate metal debris and ions that can increase the incidence of adverse tissue reactions. For cemented stems, there are at least two interfaces that can be damaged by fretting-corrosion: stem-head and stem-cement. This investigation aimed to evaluate, through in vitro and in silico analyses, fretting-corrosion at the stem-head and stem-cement interfaces, to determine which surface is most affected in pre-clinical testing and identify the causes associated with the observed behavior. Unimodular stems and femoral heads of three different groups were evaluated, defined according to the head/stem material as group I (SS/SS), group II (CoCr/SS), and group III (CoCr/CoCr). Seven pairs of stems and heads per group were tested: three pairs were subjected to material characterization, three pairs to in vitro fretting-corrosion testing, and one pair to geometric modeling in the in silico analysis. The absolute area of the stem body degraded was more than three times higher compared with the trunnion, for all groups. These results were corroborated by the in silico analysis results, which revealed that the average micromotion at the stem-cement interface (9.65-15.66 μm) was higher than that at the stem-head interface (0.55-1.08 μm). In conclusion, the degradation of the stem-cement interface is predominant in the pre-clinical set, indicating the need to consider the fretting-corrosion at the stem-cement interface during pre-clinical implant evaluations.

Biomechanical Performance of the Cemented Hip Stem with Different Surface Finish

The integrity of the cemented fixation interface is responsible for the long-term longevity of artificial hip prostheses. Metallic stems with roughened surfaces are considered to provide stronger adhesion with cement. However, clinical studies have reported that roughened stems show a lower survival rate than polished stems. These studies clearly reveal that the causes of artificial stem loosening are very complicated and multifaceted. Therefore, this study was conducted to investigate the mechanical effect of stem surface finish in cemented hip replacement. To accomplish this, a series of cement–metal specimens were tested configurations to assess the mechanical characteristics of the cement–metal interface specimens. A finite elemental model of cemented femoral prostheses was then created, in which the cement–stem interface was assumed to be in different bonding states according to the experimentally measured interface properties. The failure probabilities of the cement mantle and cemented interface under physiological loadings were evaluated. Experimental results indicate that the polished metal produced higher interfacial tensile and lower shearing strengths than the roughened metal. The polished stems were predicted to induce a lower failure probability of cement mantle and higher integrity of the cement–stem interface when compared to the roughened stem. Overall, current results provide significant evidence to support the clinical outcomes of cemented hip prostheses with different stem surface finishes.

A biomechanical testing system to determine micromotion between hip implant and femur accounting for deformation of the hip implant: Assessment of the influence of rigid body assumptions on micromotions measurements

BACKGROUND

Accurate pre-clinical evaluation of the initial stability of new cementless hip stems using in vitro micromotion measurements is an important step in the design process to assess the new stem's potential. Several measuring systems, linear variable displacement transducer-based and other, require assuming bone or implant to be rigid to obtain micromotion values or to calculate derived quantities such as relative implant tilting.

METHODS

An alternative linear variable displacement transducer-based measuring system not requiring a rigid body assumption was developed in this study. The system combined advantages of local unidirectional and frame-and-bracket micromotion measuring concepts. The influence and possible errors that would be made by adopting a rigid body assumption were quantified. Furthermore, as the system allowed emulating local unidirectional and frame-and-bracket systems, the influence of adopting rigid body assumptions were also analyzed for both concepts. Synthetic and embalmed bone models were tested in combination with primary and revision implants. Single-legged stance phase loading was applied to the implant - bone constructs.

FINDINGS

Adopting a rigid body assumption resulted in an overestimation of mediolateral micromotion of up to 49.7μm at more distal measuring locations. Maximal average relative rotational motion was overestimated by 0.12° around the anteroposterior axis. Frontal and sagittal tilting calculations based on a unidirectional measuring concept underestimated the true tilting by an order of magnitude.

INTERPRETATION

Non-rigid behavior is a factor that should not be dismissed in micromotion stability evaluations of primary and revision femoral implants.

The effect of phosphoric and phosphonic acid primers on bone cement bond strength to total hip stem alloys

Aseptic loosening at alloy-cement interfaces constitutes a main failure mechanism of cemented total hip replacements (THR). As a potential solution we investigated the effect of metal primers containing phosphoric and phosphonic acid on shear bond strength (SBS) of bone cement to THR alloys (CoCrMo, TiAlNb) and pure tin (Sn) substrates (20×8×3 mm). Metal surfaces were modified by polishing or Al₂O₃ blasting and primer application. Substrates without primer treatment served as references. Cylindrical cement pins (Ø 5mm) were polymerised onto substrate surfaces and aging (1, 5, 14 and 150 days) was simulated in aqueous NaCl solution (0.9%) before SBS determination and failure mode evaluation. Regardless of surface roughness and aging time, SBS for THR alloys and Sn was always significantly higher with primer treatment. Compared to untreated reference specimens (≤0.2MPa) SBS values increased even up to 350 fold (TiAlNb, 14 days) or 400 fold (CoCrMo, 5 days). In general, the phosphoric acid containing primer revealed significant higher SBS values on THR alloys compared to the phosphonic acid containing one. Al₂O₃ blasted specimens showed generally higher SBS values than polished ones with the exception of Sn which showed high SBS values in general. With primer treatment on polished Sn a significant reduction of SBS could not be detected even up to 150 days, whereas THR alloys showed only an SBS improvement in the short term (≤14 days). A NaCl-pitting corrosion probably led to an increasing and durable SBS on polished Sn surfaces over time. Compared to modern THR in clinical practice that shows survival rates of 10, 15, 20 or more years, the receivable bond strength enhancements described in this study appeared to be very short. The improved SBS on THR alloys lasted only a few days before it was lost again. In contrast, the phosphoric acid primer treatment of polished Sn appeared to be very promising and may play a key role in further investigations dealing with the prevention of the stem-cement debonding in THR.

Release of zirconia nanoparticles at the metal stem-bone cement interface in implant loosening of total hip replacements

In a previous failure analysis performed on femoral components of cemented total hip replacements, we determined high volumes of abraded bone cement. Here, we describe the topography of the polished surface of polymethyl methacrylate (PMMA) bone cement containing zirconia radiopacifier, analyzed by scanning electron microscopy and vertical scanning interferometry. Zirconia spikes protruded about 300nm from the PMMA matrix, with pits of former crystal deposition measuring about 400nm in depth. We deduced that the characteristically mulberry-shaped agglomerates of zirconia crystals are ground and truncated into flat surfaces and finally torn out of the PMMA matrix. Additionally, evaluation of in vitro PMMA-on-PMMA articulation confirmed that crystal agglomerations of zirconia were exposed to grain pullout, fatigue, and abrasion. In great quantities, micron-sized PMMA wear and zirconia nanoparticles accumulate in the cement-bone interface and capsular tissues, thereby contributing to osteolysis. Dissemination of nanoparticles to distant lymph nodes and organs of storage has been reported. As sufficient information is lacking, foreign body reactions to accumulated nanosized zirconia in places of long-term storage should be investigated.

STATEMENT OF SIGNIFICANCE

The production of wear particles of PMMA bone cement in the interface to joint replacement devices, presents a local challenge. The presence of zirconia particles results in frustrated digestion attempts by macrophages, liberation of inflammatory mediators, and necrosis leading to aseptic inflammation and osteolyses. Attempts to minimize wear of articulating joints reduced the attention to the deterioration of cement cuffs. We therefore investigated polished surfaces of retrieved cuffs to demonstrate their morphology and to measure surface roughness. Industrially admixed agglomerates of the radiopacifier are abraded to micron and nano-meter sized particles. The dissemination of zirconia particles in the reticulo-endothelial system to storage organs is a possible burden. Research to replace the actual contrast media by non-particulate material deserves more attention.

Digital volume correlation and micro-CT: An in-vitro technique for measuring full-field interface micromotion around polyethylene implants

Micromotion around implants is commonly measured using displacement-sensor techniques. Due to the limitations of these techniques, an alternative approach (DVC-μCT) using digital volume correlation (DVC) and micro-CT (μCT) was developed in this study. The validation consisted of evaluating DVC-μCT based micromotion against known micromotions (40, 100 and 150 μm) in a simplified experiment. Subsequently, a more clinically realistic experiment in which a glenoid component was implanted into a porcine scapula was carried out and the DVC-μCT measurements during a single load cycle (duration 20 min due to scanning time) was correlated with the manual tracking of micromotion at 12 discrete points across the implant interface. In this same experiment the full-field DVC-μCT micromotion was compared to the full-field micromotion predicted by a parallel finite element analysis (FEA). It was found that DVC-μCT micromotion matched the known micromotion of the simplified experiment (average/peak error=1.4/1.7 μm, regression line slope=0.999) and correlated with the micromotion at the 12 points tracked manually during the realistic experiment (R(2)=0.96). The DVC-μCT full-field micromotion matched the pattern of the full-field FEA predicted micromotion. This study showed that the DVC-μCT technique provides sensible estimates of micromotion. The main advantages of this technique are that it does not damage important parts of the specimen to gain access to the bone-implant interface, and it provides a full-field evaluation of micromotion as opposed to the micromotion at just a few discrete points. In conclusion the DVC-μCT technique provides a useful tool for investigations of micromotion around plastic implants.

Factors influencing initial cup stability in total hip arthroplasty

BACKGROUND

One of the main goals in total hip replacement is to preserve the integrity of the hip kinematics, by well positioning the cup and to make sure its initial stability is congruent and attained. Achieving the latter is not trivial.

METHODS

A finite element model of the cup-bone interface simulating a realistic insertion and analysis of different scenarios of cup penetration, insertion, under-reaming and loading is investigated to determine certain measurable factors sensitivity to stress-strain outcome. The insertion force during hammering and its relation to the cup penetration during implantation is also investigated with the goal of determining the initial stability of the acetabular cup during total hip arthroplasty. The mathematical model was run in various configurations to simulate 1 and 2mm of under-reaming at various imposed insertion distances to mimic hammering and insertion of cup insertion into the pelvis. Surface contact and micromotion at the cup-bone interface were evaluated after simulated cup insertion and post-operative loading conditions.

FINDINGS

The results suggest a direct correlation between under-reaming and insertion force used to insert the acetabular cup on the micromotion and fixation at the cup-bone interface.

INTERPRETATION

While increased under-reaming and insertion force result in an increase amount of stability at the interface, approximately the same percentage of surface contact and micromotion reduction can be achieved with less insertion force. We need to exercise caution to determine the optimal configuration which achieves a good conformity without approaching the yield strength for bone.

Initial instability in total ankle replacement: a cadaveric biomechanical investigation of the STAR and agility prostheses

BACKGROUND

Design improvements have increased the success of total ankle replacement, providing patients with end-stage ankle arthritis a viable alternative to arthrodesis. However, revision rates are higher than those for hip and knee arthroplasty, with the most prevalent cause of failure being aseptic loosening. The objective of this study was to quantify and compare the relative bone-implant motion patterns in two well-known total ankle replacement designs.

METHODS

A custom-designed mechanical simulator applied compressive loads (up to 300 N) and bending moments (3 Nm) to six pairs of human cadaveric ankles implanted with total ankle replacements, inducing a natural range of motion about three orthogonal axes: plantar flexion-dorsiflexion, inversion-eversion, and internal-external rotation. The implants analyzed were the Agility and the STAR (Scandinavian Total Ankle Replacement). The relative bone-implant motions for each implant component were measured with use of an optical motion capture system.

RESULTS

The Agility typically exhibited greater relative motion than the STAR, with significant differences for the tibial component in inversion-eversion (p = 0.037) and for the talar component in internal-external rotation (p = 0.039). The magnitudes of the relative motions were affected by the loading direction and by compression. The motion magnitudes were quite large, with values exceeding 1000 μm for the Agility talar component in plantar flexion-dorsiflexion and in inversion-eversion.

CONCLUSIONS

The greater magnitudes of relative motion in the Agility suggest that primary instability of the implant may contribute to its higher clinically observed aseptic loosening rate. Future total ankle replacement designs will require better fixation to improve outcomes. The results underscore the need to conduct preclinical biomechanical assessments of relative motion patterns in ankle replacements.

CLINICAL RELEVANCE

Stable initial implant fixation will likely improve clinical outcomes of total ankle replacement.

Interface abrasion between rough surface femoral stems and PMMA cement results in extreme wear volumes--a retrieval study and failure analysis

During the loosening cascade of cemented rough femoral stems, the destruction of the mantle and the production of cement and metal wear debris occur after the loss of constraint at the interface. Two-dimensional (2D) measurements (light microscopy based morphometry on fragments of mantles and vertical scanning interferometry of femoral stems) permitted mathematical 3D-extrapolations to estimate the wear volumes. Fragments of the cement mantles available lost volumes from 0.85 mm(3) to 494.10 mm(3) (median amount of bone cement wear = 178,426 mg). The harder metal surfaces lost between 1.459 mm(3) and 5.688 mm(3) of material (the median amount of metal wear per surface = 1.504 mg/100 mm(2)). Compared to the loss of material due to the fretting of stems, the abrasion of metal, and cement in defective cement mantles produced wear volumes sufficiently high to induce osteolysis. Though the design of the femoral stem and the handling of bone cement do not represent contemporary design and clinical practice, respectively, an extremely high number of joint replacements still in daily use may be impacted by this study because of possible predicted failures. Once the processes of fragmentation, abrasion, and osteolysis have been realized, the time until revision surgery should not be unduly prolonged.

Stem micromotion after femoral impaction grafting using irradiated allograft bone: a time zero in vitro study

BACKGROUND

A gamma irradiation dose of 15kGy has been shown to adequately sterilise allograft bone, commonly used in femoral impaction bone grafting to treat bone loss at revision hip replacement, without significantly affecting its mechanical properties. The objective of this study was to evaluate whether use of 15kGy irradiated bone affects the initial mechanical stability of the femoral stem prosthesis, as determined by micromotion in a comprehensive testing apparatus, in a clinically relevant time zero in vitro model of revision hip replacement.

METHODS

Morselised ovine bone was nonirradiated (control), or irradiated at 15kGy or 60kGy. For each dose, six ovine femurs were implanted with a cemented polished taper stem following femoral impaction bone grafting. Using testing apparatus that reproduces stem loading, stems were cyclically loaded and triaxial micromotion of the stem relative to the bone was measured at the proximal and distal stem regions using non-contact laser transducers and linear variable differential transformers.

FINDINGS

There were no significant differences in proximal or distal stem micromotion between groups for all directions (p≤0.80), apart for significantly greater distal stem medial-lateral micromotion in the 60kGy group compared to the 15kGy group (P=0.03), and near-significance in the anterior-posterior direction (P=0.08, power=0.85).

INTERPRETATION

Using a clinically relevant model and loading apparatus, irradiation of bone at 15kGy does not affect initial femoral stem stability following femoral impaction bone grafting.

On stabilization of loosened hip stems via cement injection into osteolytic cavities

BACKGROUND

Cement injection into osteolytic areas around the cement mantle is a technique for refixation of loose hip implants for patients who cannot undergo standard revision surgery. Preliminary clinical results show the improvement in walking distance, patients' independence and pain relief.

METHODS

In this study, we use a detailed finite element model to analyze whether cement injection into osteolytic areas contributes to the overall implant stability. We study the effect of various factors, like location and size of osteolytic areas, interface conditions and bone stiffness on bone-cement relative motion.

FINDINGS

Presented results demonstrate that the procedure is most effective for the osteolytic areas located in the proximal region of the femur, while factors like a thin layer of residual fibrous tissue around the injected cement, that was not removed during the surgery, combined with reduced bone stiffness reduce the efficiency of the procedure.

INTERPRETATION

Cement injection is able to stabilize loosened hip prostheses. However, it is important to remove the fibrous tissue layer completely, as even a thin layer will negatively influence stabilization. We will focus our research efforts on developing fibrous tissue removal techniques in order to optimize this minimally invasive treatment.