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Dolinar D, Kocjančič B, Avsec K, Šetina Batič B, Kocijan A, Godec M, Sedlaček M, Debeljak M, Grant JT, Zupanc T, Jenko M. Characterization of Micro-Threaded Stem Taper Surfaces of Cementless Hip Endoprostheses. MATERIALS (BASEL, SWITZERLAND) 2024; 17:2751. [PMID: 38894016 PMCID: PMC11173811 DOI: 10.3390/ma17112751] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/07/2024] [Revised: 05/26/2024] [Accepted: 05/29/2024] [Indexed: 06/21/2024]
Abstract
We investigated micro-threaded stem taper surface and its impact on premature failures, aseptic loosening, and infection in cementless hip endoprostheses. Our study focused on the fretting, and crevice corrosion of micro-threaded tapers, as well as the characterization of the microstructure and surface properties of two new and three retrieved Zweymüller stem tapers. The retrieved samples were selected and examined based on the head-stem taper interface being the sole source of modularity with a metallic component, specifically between the Ti alloy taper stem and the ceramic head. To determine the surface chemistry and microstructures of both new and retrieved hip endoprostheses stem taper titanium alloy, scanning -electron microscopy (SEM) was employed for morphological and microstructural analyses. Energy dispersive spectroscopy (EDS) was utilized for characterizing chemical element distribution, and electron backscattered diffraction (EBSD) was used for phase analysis. The roughness of the micro-threated stem tapers from different manufacturers was investigated using an optical profilometer, with standard roughness parameters Ra (average surface roughness) and Rz (mean peak to valley height of the roughness profile) being measured. Electrochemical studies revealed no fretting corrosion in retrieved stem tapers with ceramic heads. Consequently, three retrieved tapers and two new ones for comparison underwent potentiodynamic measurements in Hank's solution to determine the corrosion rate of new and retrieved stem taper surfaces. The results showed a low corrosion rate for both new and prematurely failed retrieved samples due to aseptic loosening. However, the corrosion rate was higher in infected and low-grade infected tapers. In conclusion, our study suggests that using ceramic heads reduces taper corrosion and subsequently decreases the incidence of premature failures in total hip arthroplasty.
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Affiliation(s)
- Drago Dolinar
- Department for Orthopaedic Surgery, University Medical Centre Ljubljana, Zaloška 9, 1000 Ljubljana, Slovenia; (D.D.); (B.K.); (K.A.); (T.Z.)
- Orthopaedic Surgery Chair, Faculty of Medicine, University of Ljubljana, Vrazov trg 2, 1000 Ljubljana, Slovenia
| | - Boštjan Kocjančič
- Department for Orthopaedic Surgery, University Medical Centre Ljubljana, Zaloška 9, 1000 Ljubljana, Slovenia; (D.D.); (B.K.); (K.A.); (T.Z.)
- Orthopaedic Surgery Chair, Faculty of Medicine, University of Ljubljana, Vrazov trg 2, 1000 Ljubljana, Slovenia
| | - Klemen Avsec
- Department for Orthopaedic Surgery, University Medical Centre Ljubljana, Zaloška 9, 1000 Ljubljana, Slovenia; (D.D.); (B.K.); (K.A.); (T.Z.)
- Orthopaedic Surgery Chair, Faculty of Medicine, University of Ljubljana, Vrazov trg 2, 1000 Ljubljana, Slovenia
| | - Barbara Šetina Batič
- Institute of Metals and Technology, Lepi pot 11, 1000 Ljubljana, Slovenia; (B.Š.B.); (A.K.); (M.G.); (M.S.)
| | - Aleksandra Kocijan
- Institute of Metals and Technology, Lepi pot 11, 1000 Ljubljana, Slovenia; (B.Š.B.); (A.K.); (M.G.); (M.S.)
| | - Matjaž Godec
- Institute of Metals and Technology, Lepi pot 11, 1000 Ljubljana, Slovenia; (B.Š.B.); (A.K.); (M.G.); (M.S.)
| | - Marko Sedlaček
- Institute of Metals and Technology, Lepi pot 11, 1000 Ljubljana, Slovenia; (B.Š.B.); (A.K.); (M.G.); (M.S.)
| | - Mojca Debeljak
- University Rehabilitation Institute Republic of Slovenia, Linhartova 51, 1000 Ljubljana, Slovenia;
| | - John T. Grant
- Research Institute, University of Dayton, Dayton, OH 45469, USA;
| | - Timon Zupanc
- Department for Orthopaedic Surgery, University Medical Centre Ljubljana, Zaloška 9, 1000 Ljubljana, Slovenia; (D.D.); (B.K.); (K.A.); (T.Z.)
| | - Monika Jenko
- MD-RI Institute for Materials Research in Medicine, Bohoričeva 5, 1000 Ljubljana, Slovenia
- MD Medicina, Sanatorium, Bohoričeva 5a, 1000 Ljubljana, Slovenia
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Diaz-Lopez RA, Wen PH, Shelton JC. Influence of Taper surface topographies on contact deformation and stresses. J Mech Behav Biomed Mater 2023; 148:106213. [PMID: 37952504 DOI: 10.1016/j.jmbbm.2023.106213] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/02/2023] [Revised: 10/16/2023] [Accepted: 10/26/2023] [Indexed: 11/14/2023]
Abstract
The role of bore and trunnion surface topography on the failure rate of total hip joint replacements due to trunnionosis is not clear despite significant variations in the design of taper components between manufacturers. Taper surface topography, along with other taper design parameters such as clearance, diameter, and assembly force, determine the initial interlock of the contacting surfaces after assembly; this has been related to relative motions that can cause fretting and corrosion at the taper interface. However, in most in-silico parametrical taper studies associated with taper micromotions, the bore and trunnion surfaces have been simplified using a flat surface and/or sinusoidal functions to mimic the surface roughness. The current study tests the hypothesis that the use of simple geometrical functions for the taper surface topography can predict the surface mechanics developed in assembled tapers. Measured and simulated surfaces of bores and trunnions were characterised using common roughness parameters and spectral density estimations. Using the same characterised surface profiles, 2D Finite Element (FE) models of CoCr alloy femoral heads and Ti alloy trunnions were developed. Models simulated assembly conditions at different resultant forces ranging from 0.5 to 4.0 kN, contact conditions were determined and associated with their topographical characteristics. Measured surfaces of bore and trunnion components comprise up to seven dominant spatial frequencies. Flattening of the trunnion microgrooved peaks was observed during the assembly of the taper. When the femoral head bore and trunnion topography were both considered a reduced number of microgrooved peaks were in contact, from 51 in an idealised taper surfaces to 35 in measured surfaces using an assembly reaction force of 4 kN. The contact points in the models developed high plastic strains, which were greater than that associated with failure of the material. Results showed that line and sine wave functions over estimate contact points at the taper interface compared to those surfaces that consider roughness and peak variation. These findings highlight the important role of modelling the full surface topography on the taper contact mechanics, as surface variations in the roughness and waviness change the performance of tapers.
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Affiliation(s)
- R A Diaz-Lopez
- School of Engineering and Materials Science, Queen Mary University of London, UK
| | - P H Wen
- School of Engineering and Materials Science, Queen Mary University of London, UK
| | - J C Shelton
- School of Engineering and Materials Science, Queen Mary University of London, UK.
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Zhang G, Yang S, Cui W, Huang Z, Zhang X, Zhang Y, Li J, Jin Z. Decomposition of micromotion at the head-neck interface in total hip arthroplasty during walking. Comput Methods Biomech Biomed Engin 2023; 26:548-558. [PMID: 35549565 DOI: 10.1080/10255842.2022.2073788] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
Abstract
Fretting corrosion as one of the leading causes for failure of modular hip prostheses has been associated with micromotion at head-neck taper junction. Decomposition of micromotion is helpful to promote the development of more realistic experiments investigating failure mechanisms of the head-neck junction in total hip arthroplasty. The aim of this study was to decompose the complex three-dimensional micromotion at the head-neck junction into multiple fundamental modes, including three translational and three rotational components. A three-dimensional finite element model composed of head-neck junction, liner and acetabular cup with a typical 12/14 taper size, as well as the taper mismatch of -4', was developed during walking. The analysis was divided into three procedures: a) the assembly simulation of the head and neck during surgery, b) verification with a simplified axisymmetric model, and c) three-dimensional modelling under normal walking. This study revealed that the main forms of micromotion contained circumferential, longitudinal micromotion and longitudinal rolling toggling, and were closely related to the state of motion. The maximum translational micromotion was predicted to be 10.9 μm during the walking gait, with the predominant modes of the circumferential translation of 9.6 μm, the longitudinal translation of 5.5 μm and the longitudinal rotation of 0.29° along the taper junction. These findings may provide design considerations for further experimental testing about fretting and facilitate the understanding of the fretting mechanisms in hip prostheses.
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Affiliation(s)
- Guoxian Zhang
- School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, China
| | - Shu Yang
- School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, China
| | - Wen Cui
- School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, China
| | - Zhi Huang
- School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, China
| | - Xiaogang Zhang
- School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, China
| | - Yali Zhang
- School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, China
| | - Junyan Li
- School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, China
| | - Zhongmin Jin
- School of Mechanical Engineering, Southwest Jiaotong University, Chengdu, China
- School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an, China
- School of Mechanical Engineering, University of Leeds, Leeds, UK
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Martelli A, Erani P, Pazzagli N, Cannillo V, Baleani M. Surface Analysis of Ti-Alloy Micro-Grooved 12/14 Tapers Assembled to Non-Sleeved and Sleeved Ceramic Heads: A Comparative Study of Retrieved Hip Prostheses. MATERIALS (BASEL, SWITZERLAND) 2023; 16:1067. [PMID: 36770073 PMCID: PMC9920329 DOI: 10.3390/ma16031067] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 10/25/2022] [Revised: 01/16/2023] [Accepted: 01/18/2023] [Indexed: 06/18/2023]
Abstract
Ti6Al4V titanium alloy (Ti-alloy) sleeved ceramic heads have become widely used in revision surgery when the hip stem is left in situ. This solution guarantees a new junction between the bore of the ceramic head and the Ti-alloy sleeve, regardless of any possible, slight surface damage to the Ti-alloy taper of the stem. However, this solution introduces an additional Ti-alloy/Ti-alloy interface pairing, which is potentially susceptible to mechanically assisted crevice corrosion. This study evaluated both qualitatively and quantitatively the damage that occurred in vivo on Ti-alloy micro-grooved 12/14 tapers of (i) primary implants with non-sleeved ceramic heads (Group 1), (ii) secondary implants with non-sleeved ceramic heads (Group 2), and (iii) secondary implants with sleeved ceramic heads (Group 3). A total of 45 explants-15 for each group, including short-, medium- and long-neck heads-underwent optical evaluation for surface damage (Goldberg scoring), surface roughness analysis, and SEM/EDX analysis. The Goldberg scores did not reveal different patterns in the tapers' surface damage; surface damage was classified as absent or mild (surface damage score ≤2) in 94%, another 94%, and 92% of the analysed regions for Group 1, Group 2, and Group 3, respectively. Small but significant differences in morphological changes occurred in the tapers of the three groups: reductions no greater than a few percentage points in median values of roughness parameters were found in Group 1 and Group 2, while negligible changes were found in Group 3. SEM/EDX analysis revealed little (i.e., a slight increase in the oxygen content) to undetectable changes in the chemical composition on the Ti-alloy surface independently of the group. These results suggest that the Ti-alloy/Ti-alloy sleeve/taper junction is only mildly susceptible to mechanically assisted crevice corrosion. Assembling a sleeved ceramic head, with variable neck lengths up to a "long-neck", to a Ti-alloy micro-grooved 12/14 taper of a stem left in situ does not seem to increase the risk of revision due to trunnionosis, as long as junction stability (i.e., the proper seating of the sleeved ceramic head on the 12/14 taper) is achieved intraoperatively.
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Affiliation(s)
- Andrea Martelli
- Laboratorio di Tecnologia Medica, IRCCS Istituto Ortopedico Rizzoli, 40136 Bologna, Italy
- Dipartimento di Ingegneria Enzo Ferrari, Università degli Studi di Modena e Reggio Emilia, 41125 Modena, Italy
| | - Paolo Erani
- Laboratorio di Tecnologia Medica, IRCCS Istituto Ortopedico Rizzoli, 40136 Bologna, Italy
| | - Nicola Pazzagli
- Laboratorio di Tecnologia Medica, IRCCS Istituto Ortopedico Rizzoli, 40136 Bologna, Italy
| | - Valeria Cannillo
- Dipartimento di Ingegneria Enzo Ferrari, Università degli Studi di Modena e Reggio Emilia, 41125 Modena, Italy
| | - Massimiliano Baleani
- Laboratorio di Tecnologia Medica, IRCCS Istituto Ortopedico Rizzoli, 40136 Bologna, Italy
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Feyzi M, Fallahnezhad K, Taylor M, Hashemi R. An Overview of the Stability and Fretting Corrosion of Microgrooved Necks in the Taper Junction of Hip Implants. MATERIALS (BASEL, SWITZERLAND) 2022; 15:8396. [PMID: 36499893 PMCID: PMC9735617 DOI: 10.3390/ma15238396] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 10/14/2022] [Revised: 11/21/2022] [Accepted: 11/22/2022] [Indexed: 06/17/2023]
Abstract
Fretting corrosion at the head-neck interface of modular hip implants, scientifically termed trunnionosis/taperosis, may cause regional inflammation, metallosis, and adverse local tissue reactions. The severity of such a deleterious process depends on various design parameters. In this review, the influence of surface topography (in some cases, called microgrooves/ridges) on the overall performance of the microgrooved head-neck junctions is investigated. The methodologies together with the assumptions and simplifications, as well as the findings from both the experimental observations (retrieval and in vitro) and the numerical approaches used in previous studies, are presented and discussed. The performance of the microgrooved junctions is compared to those with a smooth surface finish in two main categories: stability and integrity; wear, corrosion, and material loss. Existing contradictions and disagreements among the reported results are reported and discussed in order to present a comprehensive picture of the microgrooved junctions. The current research needs and possible future research directions on the microgrooved junctions are also identified and presented.
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Dos Santos VO, Cubillos PO, Dos Santos CT, Fernandes WG, de Jesus Monteiro M, Caminha IMV, Moré ADO, de Mello Roesler CR. Pre-clinical evaluation of fretting-corrosion at stem-head and stem-cement interfaces of hip implants using in vitro and in silico models. J Biomed Mater Res B Appl Biomater 2022; 110:2521-2532. [PMID: 35779044 DOI: 10.1002/jbm.b.35110] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/30/2020] [Revised: 10/06/2021] [Accepted: 01/15/2022] [Indexed: 11/07/2022]
Abstract
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.
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Affiliation(s)
- Vinícius Oliveira Dos Santos
- Biomechanical Engineering Laboratory (LEBm), University Hospital, Department of Mechanical Engineering, Federal University of Santa Catarina (UFSC), Florianópolis, Santa Catarina, Brazil
| | - Patricia Ortega Cubillos
- Biomechanical Engineering Laboratory (LEBm), University Hospital, Department of Mechanical Engineering, Federal University of Santa Catarina (UFSC), Florianópolis, Santa Catarina, Brazil
| | | | | | | | | | - Ari Digiácomo Ocampo Moré
- Biomechanical Engineering Laboratory (LEBm), University Hospital, Department of Mechanical Engineering, Federal University of Santa Catarina (UFSC), Florianópolis, Santa Catarina, Brazil.,Polydoro Ernani de São Thiago University Hospital, Federal University of Santa Catarina, Florianópolis, SC, Brazil
| | - Carlos Rodrigo de Mello Roesler
- Biomechanical Engineering Laboratory (LEBm), University Hospital, Department of Mechanical Engineering, Federal University of Santa Catarina (UFSC), Florianópolis, Santa Catarina, Brazil
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Shirazi HA, Chan CW, Lee S. Elastic-plastic properties of titanium and its alloys modified by fibre laser surface nitriding for orthopaedic implant applications. J Mech Behav Biomed Mater 2021; 124:104802. [PMID: 34474322 DOI: 10.1016/j.jmbbm.2021.104802] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/02/2021] [Revised: 08/22/2021] [Accepted: 08/26/2021] [Indexed: 11/26/2022]
Abstract
Laser nitriding is one of the most promising approaches to improve wear resistance of Ti alloy surfaces and may extend the use in orthopaedic implants. In this study, three types of Ti alloys, namely alpha commercially pure Ti ("TiG2"), alpha-beta Ti-6Al-4V ("TiG5"), and beta Ti-35.5Nb-7.3Zr-5.7Ta ("βTi"), were subjected to an open-air laser nitriding treatment. Essential elastic-plastic mechanical properties including elastic modulus, hardness, elastic energy, plasticity index, and hardness-to-elasticity ratio of the laser-treated Ti alloys were characterized using nanoindentation experiment. The results showed that the elastic modulus, hardness and elastic energy values of all Ti samples significantly increased in the nitrided layer compared to respective bare substrates for all three Ti materials. Across different Ti samples, βTi sustained its relatively lower elastic modulus, but presented comparable hardness, elastic energy, plasticity index, as well as hardness-to-elasticity ratio in the nitrided layer compared to the other two Ti alloys. Overall, amongst three medical grade Ti alloys in this study, βTi appeared as the most appealing candidate for joint replacement applications even solely in view of mechanical compatibility when combined with surface laser nitriding. Nevertheless, laser nitriding treatment in this study tended to cause a residual compressive stress on all Ti alloys as displayed by cracks developed in the nitrided layer and analyzed on βTi by X-ray diffraction (XRD) and further nanoindentation tests.
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Affiliation(s)
- Hadi Asgharzadeh Shirazi
- Department of Mechanical Engineering, Technical University of Denmark, Kgs. Lyngby DK, 2800, Denmark
| | - Chi-Wai Chan
- Bioengineering Research Group, School of Mechanical and Aerospace Engineering, Queen's University Belfast, BT9 5AH, UK
| | - Seunghwan Lee
- Department of Mechanical Engineering, Technical University of Denmark, Kgs. Lyngby DK, 2800, Denmark.
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