Enhanced lubricant film formation through micro-dimpled hard-on-hard artificial hip joint: An in-situ observation of dimple shape effects

Cartilage-inspired surface textures for improved tribological performance of orthopedic implants

Joint replacements have become one of the most common orthopedic procedures due to the significant demands of retaining functional mobility. While these procedures are of great value to patients, there are some limitations. Durability is the most important limitation associated with joint replacement that needs to be addressed due to the increasing number of younger patients. Titanium is a commonly used implant material which has high biocompatibility, high strength-to-density ratio, and high corrosion resistance. However, current titanium implants have poor wear resistance which shortens their lifespan. In this study, microscale dimples with four different dimple shapes (circular, triangular, square, and star) of similar sizes to the pores found in natural articular cartilage were fabricated on titanium disks to improve implant lubrication and reduce wear. Biotribology tests were performed on dimpled and non-dimpled titanium disks in a condition similar to that inside of a patient's body. It was shown that dimpling the titanium disks optimized the lubricant film formation and decreased the wear rate significantly while also reducing the coefficient of friction (COF). The star-shaped dimples had the lowest COF and almost no detectable wear after 8 h of testing. To investigate whether dimpling increased bacterial colonization due to increased surface area, and to determine whether any increase could be limited by coating with antibacterial materials, bacterial colonization with Staphylococcus aureus was tested with non-dimpled and star-shaped dimpled titanium disks with and without coating with polydopamine (PDA), silver (Ag) nanoparticles (NPs), and PDA + Ag NPs. It was found that dimpling did not increase bacterial colonization, and that coating with PDA, Ag NPs, or PDA + Ag NPs did not decrease bacterial colonization. Nevertheless, we conclude that star-shaped dimpled titanium surfaces have potential utility as more durable orthopedic implants.

Water droplet can mitigate dust from hydrophobized micro-post array surfaces

Water droplet rolling motion over the hydrophobized and optically transparent micro-post array surfaces is examined towards dust removal pertinent to self-cleaning applications. Micro-post arrays are replicated over the optically transparent polydimethylsiloxane (PDMS) surfaces. The influence of micro-post array spacing on droplet rolling dynamics is explored for clean and dusty surfaces. The droplet motions over clean and dusty micro-post array surfaces are monitored and quantified. Flow inside the rolling droplet is simulated adopting the experimental conditions. Findings reveal that micro-post gap spacing significantly influences droplet velocity on clean and dusty hydrophobized surfaces. Air trapped within the micro-post gaps acts like a cushion reducing the three-phase contact line and interfacial contact area of the rolling droplet. This gives rise to increased droplet velocity over the micro-post array surface. Droplet kinetic energy dissipation remains large for plain and micro-post arrays with small gap spacings. A Rolling droplet can pick up dust particles from micro-post array gaps; however, few dust residues are observed for large gap spacings. Nevertheless, dust residues are small in quantity over hydrophobized micro-post array surfaces.

Study on tribological performance of groove-textured bioimplants

Surface texturing is an effective approach to improve the tribological performance of artificial joints. In this paper, the frictional performance of Ultra-High-Molecular-Weight-Polyethylene and Cobalt-Chromium-Molybdenum material combination with micro grooves fabricated on the metal bearings is studied. The results show that grooves with width of 500 μm, depth of 4.5 μm and pitch distance of 3 mm could provide the optimized tribological performance, the coefficient of friction of which can be down to 0.05 showing a reduction of 51.9% compared to that of polished samples without micro grooves. A two-dimensional simulation of hydrodynamic pressure, based on Reynolds equation, is conducted. It is concluded that hydrodynamic pressure has little effect on the improved tribological performance of textured bioimplants. Otherwise, second lubrication effect induced by the polymer plastic deformation is proved to play a major role in the reduction of coefficient of friction.

Surface Texturing of Prosthetic Hip Implant Bearing Surfaces: A Review

More than 300,000 total hip replacement surgeries are performed in the United States each year to treat degenerative joint diseases that cause pain and disability. The statistical survivorship of these implants declines significantly after 15-25 years of use because wear debris causes inflammation, osteolysis, and mechanical instability of the implant. This limited longevity has unacceptable consequences, such as revision surgery to replace a worn implant, or surgery postponement, which leaves the patient in pain. Innovations such as highly cross-linked polyethylene and new materials and coatings for the femoral head have reduced wear significantly, but longevity remains an imminent problem. Another method to reduce wear is to add a patterned microtexture composed of micro-sized texture features to the smooth bearing surfaces. We critically review the literature on textured orthopedic biomaterial surfaces in the context of prosthetic hip implants. We discuss the different functions of texture features by highlighting experimental and simulated results documented by research groups active in this area. We also discuss and compare different manufacturing techniques to create texture features on orthopedic biomaterial surfaces and emphasize the key difficulties that must be overcome to produce textured prosthetic hip implants.

The Effect of Texture Floor Profile on the Lubricant Film Thickness in a Textured Hard-On-Soft Bearing With Relevance to Prosthetic Hip Implants

Polyethylene wear debris limits the longevity of prosthetic hip implants. We design a pattern of axisymmetric texture features to increase hydrodynamic pressure and lubricant film thickness and, thus, reduce solid-on-solid contact, friction, and wear in hard-on-soft prosthetic hip implant bearings. Specifically, we study the effect of the texture floor profile on the lubricant film thickness using a soft elastohydrodynamic lubrication model. We compute the optimum texture parameters that maximize the lubricant film thickness for different texture floor profiles, as a function of bearing operating conditions. Flat texture floor profiles create thicker lubricant films than sloped or curved texture floor profiles for their respective optimum texture design parameters. We find that the texture feature volume is the most important parameter in terms of maximizing the lubricant film thickness, because a linear relationship exists between the texture feature volume with optimum texture parameters and the corresponding optimum lubricant film thickness, independent of the texture floor profile.

Maximizing the Lubricant Film Thickness Between a Rigid Microtextured and a Smooth Deformable Surface in Relative Motion, Using a Soft Elasto-Hydrodynamic Lubrication Model

We design a pattern of microtexture features to increase hydrodynamic pressure and lubricant film thickness in a hard-on-soft bearing. We use a soft elastohydrodynamic lubrication model to evaluate the effect of microtexture design parameters and bearing operating conditions on the resulting lubricant film thickness and find that the maximum lubricant film thickness occurs with a texture density between 10% and 40% and texture aspect ratio between 1% and 14%, depending on the bearing load and operating conditions. We show that these results are similar to those of hydrodynamic textured bearing problems because the lubricant film thickness is almost independent of the stiffness of the bearing surfaces in full-film lubrication.

Ring-Shaped Surface Microstructures for Improved Lubrication Performance of Joint Prostheses

The microstructuring of surfaces is a highly researched field that is aimed at enhancing the tribological behavior of sliding surfaces such as artificial joints, which are subject to wear. Lubrication of the joint interface plays a key role in the wear process, although the mechanisms of lubrication are quite complex. In order to improve the lubrication, the surfaces of the articulating components can be modified by pulsed femtosecond-laser microstructuring. Through microstructuring, the apparent dynamic viscosity of the synovial fluid between the artificial joint can be increased due to its non-Newtonian properties. This may lead to better hydrodynamic lubrication and, therefore, reduced particle abrasion. Femtosecond laser-induced microstructures were investigated in a modified rheometer setup featuring a reduced gap size in order to reproduce and measure the interface between fluid and implant surface more accurately. As a test fluid, a synovial fluid substitute was used. The study has shown that an increase in the viscosity of the synovial fluid substitute can be achieved by microstructuring. Compared to a smooth implant surface, the apparent viscosity of the synovial fluid substitute increased by over 30% when ring-shaped microstructures of 100 µm diameter with an aspect ratio of 0.66 were implemented.

Characteristics of different cathodic arc deposition coatings on CoCrMo for biomedical applications

Coatings of endoprostheses are used to improve the tribological performance of arthroplasties. A major challenge for the successful use of these coatings, however, is a stable layer adhesion, a smooth surface, as well as a reduction in droplet formation during the coating process. Explants with commercially available coatings were investigated to assess surface/layer defects and adhesion properties. For the investigation of new coatings, we used cathodic arc deposition (Arc-PVD) to generate TiN, ZrN similar to the currently commercially available coatings and three different diamond like carbon (DLC) coatings on CoCrMo substrate. All surface coatings were mechanically specified by measuring roughness, coating thickness, abrasive wear and critical loads. A friction wear test was modified using an UHMWPE counterpart with a contact pressure of 10 MPa to compare different coatings in one tribological test setup. Calf serum was used as lubricant. The commercially used coatings on the retrieved explants show several defects and the critical load for coating failure varied widely. All produced surface coatings showed an increased surface roughness after coating compared to uncoated samples, which was due to droplet formation, especially in the DLC coatings. A diamond post-polishing process was performed to reduce the surface roughness and reach the ISO standard of R_a < 50 nm. The ZrN and TiN coatings exhibited a decreased friction after removing of the droplets in comparison to uncoated CoCrMo samples, indicating that the post-polishing process might be a useful tool to ameliorate the tribological performance. The friction coefficient for all tested DLC layers was more than two times increased compared to the CoCrMo samples. The use of hard/soft bearings with DLC coated endoprostheses seems to be not advantageous.