Mechanisms of plastic deformation in highly cross-linked UHMWPE for total hip components--the molecular physics viewpoint

Influence of plane-strain compression on the microstructure and tribological behavior of GUR 1050 UHMWPE

Ultra-high molecular weight polyethylene (UHMWPE) has been used as a bearing surface in orthopedic implants due to its outstanding physical and mechanical properties. Modifications in the structure of the polymer have a direct effect on its wear. In this work, plane-strain compression in a channel die was applied to induce microstructural changes in specimens of UHMWPE GUR 1050. These structural changes were characterized using a combined approach involving Raman spectroscopy and atomic force microscopy. These qualitative and quantitative characterization resulted in a valuable understanding of the changes in the material microstructure when subjected to plastic deformation. A molecular non-uniform alignment of the UHMWPE molecules, with fragmentation and kinking of polymer lamellae, was observed in the direction of material flow, perpendicular to the compressive load direction, following an inhomogeneous strain field generated by the mechanical compression. The microstructural analyses revealed an increased crystalline content and decreased intermediate phase while amorphous phase content remained unchanged, in all the regions of the deformed specimen. The tribological performance, evaluated by the scratch resistance force, decreased along the material flow direction and increased along the load direction in the deformed polymer compared to that of the uncompressed polymer. Plane-strain compression was able to modify the polymer microstructure, introducing directional anisotropy in its tribological behavior that can impact the wear performance of the material.

Large Femoral Heads in Total Hip Arthroplasty With Vitamin E Highly Cross-Linked Polyethylene: Head Penetration Rates Compared to Highly Cross-Linked Polyethylene

BACKGROUND

Highly cross-linked polyethylene with vitamin E (VE-HXLPE) has shown superior tribological properties and has been rapidly adopted in total hip arthroplasty. However, the majority of studies compare VE-HXLPE to conventional or moderately cross-linked polyethylene using standard femoral head sizes. This study's purpose was 2-fold: (1) compare radiographic femoral head penetration (FHP) between VE-HXLPE and HXLPE and (2) evaluate FHP in large femoral heads ≥40 mm.

METHODS

One hundred forty-two consecutive primary total hip arthroplasties using ceramic femoral heads (n = 84 VE-HXLPE; n = 58 HXLPE) in a single implant system were retrospectively reviewed. FHP was measured radiographically utilizing Martell method at 4-week, 1-year, and latest radiographs. FHP, cup position, and demographic variables were compared between VE-HXLPE and HXLPE liners.

RESULTS

Median linear FHP was lower for VE-HXLPE compared to HXLPE during the initial "bedding-in" period between 4-week and 1-year (0.383 vs 0.551 mm, P = .650) and between 1-year and latest follow-up (0.131 vs 0.270 mm/y, P = .636) although without statistical significance. Acetabular cup inclination and anteversion did not influence linear or volumetric FHP (P ≥ .204). Large femoral heads (≥40 mm) were predictive of higher FHP during the early bedding-in period (P ≤ .025) but did not have an effect beyond 1 year in multivariate regression with numbers available. No radiographic osteolysis was observed in any case.

CONCLUSION

These findings support others that VE-HXLPE is the optimal polyethylene bearing surface to minimize FHP during the bedding-in period and beyond. Surprisingly, large ceramic femoral heads appear to influence FHP during the initial bedding-in period but do not increase FHP beyond 1 year. Further longer term follow-up remains warranted.

LEVEL OF EVIDENCE

III.

To what extent could the acetabular liner thickness be reduced yet remaining tribologically acceptable in metal-on-vitamin E-diffused crosslinked polyethylene hip arthroplasty?

The aim of the present study was to evaluate how much reduction in acetabular liner thickness could be tribologically acceptable in metal-on-vitamin-E diffused highly crosslinked ultra-high molecular weight polyethylene (Vit-E XLPE) bearings for total hip arthroplasty. We tested thick- (10.3 mm), moderate- (6.3 mm), and thin- (4.3 mm) Vit-E XLPE liners coupled with 28-mm cobalt-chromium femoral heads on a hip simulator to 5 million cycles, and peak contact stress was predicted based on mathematical modeling. Wear damage was also evaluated in terms of surface topology and morphology. Wear simulation demonstrated that the 2-4 mm thickness reduction (6.3 → 4.3 mm and 10.3 → 6.3 mm) did not significantly affect the wear rate for Vit-E XLPE liner, whereas 6-mm reduction (10.3 → 4.3 mm) significantly increased liner wear (by 309%) and head roughness (by 415%). This effect was attributed to a contact stress increase (by 24-41%). However, the wear rates for all thicknesses tested were much lower than those previously reported for thicker non-crosslinked materials. The original crystalline morphology was maintained in all liners after wear. Our results suggest that the 2-4 mm thickness reduction may be tribologically acceptable in Vit-E XLPE liners. However, more severe and longer term simulations are necessary to determine a minimum acceptable thickness.

Effect of PEW and CS on the Thermal, Mechanical, and Shape Memory Properties of UHMWPE

Modified ultra-high-molecular-weight polyethylene (UHMWPE) with calcium stearate (CS) and polyethylene wax (PEW) is a feasible method to improve the fluidity of materials because of the tense entanglement network formed by the extremely long molecular chains of UHMWPE, and a modified UHMWPE sheet was fabricated by compression molding technology. A Fourier-transform infrared spectroscopy test found that a new chemical bond was generated at 1097 cm-1 in the materials. Besides, further tests on the thermal, thermomechanical, mechanical, and shape memory properties of the samples were also conducted, which indicates that all properties are affected by the dimension and distribution of crystal regions. Moreover, the experimental results indicate that the addition of PEW and CS can effectively improve the mechanical properties. Additionally, the best comprehensive performance of the samples was obtained at the PEW content of 5 wt % and the CS content of 1 wt %. In addition, the effect of temperature on the shape memory properties of the samples was investigated, and the results indicate that the shape fixity ratio (Rf) and the shape recovery ratio (Rr) can reach 100% at 115 °C and 79% at 100 °C, respectively, which can contribute to the development of UHMWPE-based shape memory polymers.

Influence of liner offset and locking mechanism on fatigue durability in highly cross-linked polyethylene total hip prostheses

Highly cross-linked, ultrahigh molecular weight polyethylene (HXLPE) acetabular liners are inherently associated to a risk of fatigue failure due to femoral neck impingement. Different thicknesses and designs employed with HXLPE liners greatly affect mechanical loading scenario. The purpose of this study was to clarify the influence of liner offset (lateralization) and locking mechanism (presence/absence of anti-rotation tabs in the external surface) on fatigue durability in annealed and vitamin E-blended HXLPE liners with a current commercial design. Each liner tested had six anti-rotation tabs, which were engaged in the 6 of 12 recesses on the metal shell. The remaining six recesses had no direct contact with the liner, where HXLPE was mechanically unsupported by the metal backing. These mated and/or unmated rim regions in the offset (2, 3, 4-mm lateralized) liners were exposed to severe neck impingement until crack propagation was identified. Phase volume percentages (crystalline, amorphous, and intermediate phase contents) of HXLPE liners were compared before and after impingement in order to interpret differences in impingement micromechanics associated with the rim design variations. Our results showed that the presence of unmated recesses served as a stress concentrator due to the formation of millimeter-scale gaps between the liner and shell. Another potential design problem drawn from our study was liner offset associated with a small volume protruding above the metal rim. Therefore, surgeons should take special care in selecting locking designs and geometries especially when using HXLPE offset liners.

Femoral Head Penetration Rates of Second-Generation Sequentially Annealed Highly Cross-Linked Polyethylene at Minimum Five Years

BACKGROUND

Highly cross-linked polyethylene (HXLPE) liners in total hip arthroplasty (THA) have demonstrated decreased wear rates, resilience to cup orientation, and reduced osteolysis compared to conventional polyethylene. Sequential irradiation and annealing below the melting temperature is unique compared to most HXLPE which is irradiated and remelted. This study purpose is to provide minimum 5-year femoral head penetration rates of sequentially annealed HXLPE in primary THA.

METHODS

A retrospective review of a prospectively collected database identified 198 consecutive, cementless primary THAs utilizing sequentially annealed HXLPE (X3; Stryker, Mahwah, NJ). Operative technique was standardized. Radiographs were analyzed utilizing the Martell method with minimum 5-year and 1-year radiographs as baseline to minimize the initial bedding-in period.

RESULTS

Seventy-seven hips with minimum 5-year follow-up were analyzed. Mean steady state linear and volumetric head penetration rates were 0.095 mm/y and 76 mm³/y, respectively. Volumetric head penetration was significantly less for 32-mm compared to 36-mm (P = .028). In addition, less head penetration was observed for ceramic 32-mm heads at nearly half the rate compared to cobalt-chromium 36-mm heads (P ≥ .092). No correlations existed between penetration rates and age, body mass index, University of California Los Angeles Activity Level, polyethylene thickness, cup inclination, or anteversion (P ≥ .10). No radiographic osteolysis was observed.

CONCLUSION

Surprisingly, linear head penetration rates of sequentially annealed HXLPE were nearly identical to the osteolysis threshold for conventional polyethylene and greater than reports of irradiated and remelted HXLPE. Furthermore, these data corroborate reports that HXLPE is resilient to cup orientation and demographic variables. Longer term follow-up is recommended.

Elastoplastic behavior of highly cross-linked and vitamin E-stabilized polyethylene - A biomechanical study

BACKGROUND

Vitamin E-stabilized cross-linked polyethylene has been touted to alleviate the negative effects of oxidation. Although it has demonstrated significant improvements in wear resistance, bio-tribology, and oxidative resistance, little is known about the effect of antioxidants and dosage of cross-linking on the mechanical strength. This study aimed to evaluate the mechanical properties of these novel materials, which are commonly used in orthopedic implants.

METHODS

Samples of different polymers were prepared with various levels of cross-linking and with or without vitamin E-stabilization and then tested according to ASTM D695 and D638. The elastoplastic characteristics under compression and tension were compared between the groups.

FINDINGS

Vitamin E-stabilized cross-linked polyethylene showed a significant increase in elastic modulus over other groups, with a maximum increase of 26% in compression and 40% in tension when compared to the highly cross-linked group without vitamin E stabilization. The elastoplastic behavior under compression differed to that in tension for all polymers, demonstrating the anisotropic characteristics of these polymers.

INTERPRETATION

The lower mechanical strength of highly cross-linked polyethylene has been a complication with the use of this polymer in orthopedic liners. This current study suggests that vitamin E-stabilized cross-linked polyethylene could be a suitable alternative material for knee implants because of its improved strength in resisting external forces.

Contemporary Dual Mobility Head Penetration at Five Years: Concern for the Additional Convex Bearing Surface?

BACKGROUND

Dual mobility (DM) bearings are increasingly popular and second-generation designs contain highly cross-linked polyethylene. The purpose of this study is to report head penetration rates in modern DM bearings.

METHODS

A review of 63 consecutive DM bearings was performed. Radiographs were analyzed for head penetration using Martell methodology at regular postoperative intervals.

RESULTS

Thirty-four DM bearings were analyzed. Mean linear head penetration was 1.59 mm/y at 1 year, 1.07 mm/y at 2 years, and 0.27 mm/y at 5 years following an exponential regression model (R² = 0.999). Mean volumetric wear was 783 mm³/y at 1 year, 555 mm³/y at 2 years, and 104 mm³/y at 5 years following an exponential regression model (R² = 0.986).

CONCLUSION

Initial head penetration of DM bearings is larger than contemporary cross-linked polyethylene bearings; however, rates approach steady state after 2 years, analogous to traditional bearings. The larger "bedding-in" head penetration may be due to the additional convex bearing surface, creating 2 surfaces for deformation/wear.

Vitamin E-stabilized highly crosslinked polyethylenes: The role and effectiveness in total hip arthroplasty

Morphology and design of ultra-high molecular weight polyethylene (UHMWPE or simply PE) acetabular components used in total hip arthroplasty (THA) have been evolving for more than half a century. Since the late-1990s, there were two major technological innovations in PE emerged from necessity to overcome the wear-induced periprosthetic osteolysis, i.e., the development of highly crosslinked PEs (HXLPEs). There are many literature reporting that radiation crosslinked and remelted/annealed (first-generation) HXLPEs markedly reduced the incidence of osteolysis and aseptic loosening. Regardless of such clinical success in the first-generation technologies, there were some recent shifts in Japan toward the use of new second-generation HXLPEs subjected to sequential irradiation/annealing or antioxidant vitamin E (α-tocopherol) incorporation. Although the selection rate of first-generation liners still account for more than half of all the PE THAs (∼58% in 2015), the use of vitamin E-stabilized liners has been steadily growing each year since their clinical introduction in 2010. In these contexts, it is of great importance to evaluate and understand the real clinical benefits of using the new second-generation liners as compared to the first generation. This article first summarizes structural evolution and characteristic features of first-generation HXLPEs, and then provides a detailed description of second-generation antioxidant HXLPEs in regard to the role of vitamin E incorporation on their chemical and mechanical performances in THA.

Improved Resistance to Neck-Liner Impingement in Second-Generation Highly Crosslinked Polyethylene-The Role of Vitamin E and Crosslinks

BACKGROUND

Radiation crosslinking of ultrahigh molecular weight polyethylene (UHMWPE) results in the reduced tensile strength and fracture toughness as an expense of dramatic increase in the wear resistance. Clinical rim fracture has been reported due to neck-liner impingement on a first-generation highly crosslinked UHMWPE acetabular component. The objective of this study was to investigate whether a second-generation, vitamin E-blended highly crosslinked UHMWPE possesses the improved impingement resistance.

METHODS

Cyclic impingement testing was performed in a variety of UHMWPE acetabular components (vitamin E free or blended, noncrosslinked or highly crosslinked, and GUR1050 or GUR1020) with the same design specification. The kinematics used to reproduce the neck-liner impingement was a uniaxial fatigue compression in concert with an axial rotational torque. After the test, the geometry and morphological changes were characterized by coordinate measuring machine, scanning electron microscopy, and confocal Raman microspectroscopy.

RESULTS

A total of 300-kGy irradiated and annealed GUR1050 liner resulted in a significant geometry change and microcracks on the rim surface after the test. However, regardless of the similar level of crosslinking, much less damage was noted in the 300-kGy irradiated GUR1050 liner blended with vitamin E at a concentration of 3000 ppm. On the other hand, vitamin E-blended noncrosslinked GUR1050 exhibited an extensive microscopic fibrillation and folding on the impinged surface.

CONCLUSION

These results suggest that vitamin E-blending into UHMWPE has compensated the negative effect of toughness decrease induced by radiation crosslinking. We concluded that the coexistence of vitamin E and crosslinks can restrain impingement damage more effectively than either of them.

Size and thickness effect on creep behavior in conventional and vitamin E-diffused highly crosslinked polyethylene for total hip arthroplasty

Since the early 2000s, the use of large femoral heads is becoming increasingly popular in total hip arthroplasty (THA), which provides an improved range of motion and joint stability. Large femoral heads commonly necessitate to be coupled with thinner acetabular liners than the conventionally used because of the limited sizes of outer shells (especially for patients with small pelvic size). However, the influence of the liner thinning on the mechanical performance is still not clearly understood. The objective of this study was to experimentally clarify the size and thickness effect on the rates of compressive creep strain in conventional (virgin low-crosslinked) and vitamin E-diffused highly crosslinked, ultra-high molecular weight polyethylene (UHMWPE) acetabular liners. We applied uniaxial compression to these liners of various internal diameters (28, 32 and 36mm) and thicknesses (4.8, 6.8 and 8.9mm) up to 4320min under the constant load of 3000N. Vitamin E-diffused highly crosslinked UHMWPE components showed significantly greater creep resistance than the conventional ones. In the both types of UHMWPE, the rates of creep strain significantly decreased by increasing the internal diameter and thickness. Varying the component thickness contributed more largely to the creep behavior rather than the internal diameter. Our results suggest the positive mechanical advantage of using large femoral heads, but at the same time, a considerable liner thinning is not recommended for minimizing creep strain. Therefore, the further in-vitro as well as in-vivo research are necessary to conclude the optimal balance of head diameter and liner thickness within the limited sizes of outer shells.

Photodegradation of UHMWPE Compounded with Annatto and Beetroot Extracts

We observed the anti-UV action of beetroot extract in an ultra-high molecular weight (UHMWPE) matrix. The beetroot extract and the one prepared from annatto seed also acted efficiently as pigment to the same polymeric matrix. Neat UHMWPE and UHMWPE compounded with annatto and beet extract were compression molded and tensile specimens were obtained from the molded plates and submitted to UV radiation for up to 42 days. Tensile tests were performed and it was observed that the beet extract had a stabilizing action in the polymer compared to neat polymer and the one with annatto extract. Complementary analyses showed good homogenization of the extracts through the polymer matrix indicating the possibility of use as pigment, although the annatto extract appeared to be very unstable under irradiation. Spectroscopic characterization helped to explain the stability of the extracts before and after molding.

Effects of vitamin E blending on plastic deformation mechanisms of highly crosslinked ultrahigh molecular weight polyethylene (HXL-UHMWPE) in total hip arthroplasty

The molecular mobility and crystalline texture development in highly crosslinked ultrahigh molecular weight polyethylene (HXL-UHMWPE) blended with antioxidant vitamin E (VE, dl-α-tocopherol) were studied via uniaxial compression at room temperature by means of confocal/polarized Raman spectroscopy. The results were compared to morphological analyses under the same compression conditions performed on HXL-UHMWPE prepared in exactly the same way but blending VE into the polyethylene resin (VE-free HXL-UHMWPE). These comparative analyses allow us to evaluate the physical role of VE in morphological alterations of HXL-UHMWPE induced by compression deformation, which can greatly affect its micromechanical behavior. Molecular rearrangement and phase transitions in crystalline and non-crystalline phase, i.e. amorphous and intermediate (third) phase, were found to be part of a reconstruction process after plastic deformation in the samples. Although VE-blended HXL-UHMWPE exhibited more pronounced molecular mobility, as evidenced by its significant deformation-induced texturing, crystallinity change was totally inhibited by the presence of VE during deformation. On the other hand, amorphous-to-intermediate phase transition was confirmed. VE-free HXL-UHMWPE also presented significant crystallization after deformation, but its surface texture evolution occurred to a much lesser extent. This study suggests that the addition of VE induced earlier activation of compression deformation modes in crystalline and non-crystalline phases (e.g. chain slip, interlamellar shear and rotation) due to an increase in polyethylene chain mobility.