Accuracy of methods for calculating volumetric wear from coordinate measuring machine data of retrieved metal-on-metal hip joint implants

A new approach to identify wear regions on bearing surfaces of retrieved endoprostheses

Although total hip replacements (THR) can be considered one of the most successful implantable medical devices in history, wear remains the ultimate challenge in order to further increase clinical success. Wear assessment on retrieved implants is the most reliable way to perform research into failure mechanisms. Therefor the bearing surface of the explant is measured geometrically by coordinate measuring machine (CMM). Wear determination in geometrical data is carried out in 3 steps: (1) identifying the worn area, (2) reconstructing the pre-wear geometry and (3) quantify wear as the difference between worn area and pre-wear geometry. In previous studies, assumptions to pre-wear geometry had been made for wear determination (step 2) and the worn area was identified by deviations between measured data and assumed form. Thus, the original form of the retrieved endoprostheses, including form deviations due to the manufacturing process and implantation, was not considered which leads to uncertainties in the wear computed. This work introduces a method which allows to identify the wear area without making assumptions to the original form. Instead, the curvature of the bearing surface obtained by simple computations on the measurement data is analysed and the edge of the wear region is recognized by its deviation in curvature. The method is applied to a retrieved Metal-on-Metal prosthetic head and the results are compared to those of the well-known method introduced by Jaeger et al., in 2013. With the new approach the wear region is identified more accurately.

Taper Material Loss in Total Hip Replacements: Is It Affected by Joint Friction?

BACKGROUND

Metal debris and corrosion products generated from the taper junctions of modular joint replacements have been recognized as contributors to failure. Therefore, understanding the factors associated with increased taper wear and corrosion is fundamental to improving implant performance.

METHODS

A cohort of 85 large-diameter metal-on-metal heads and cups retrieved at revision surgery, after 10 to 96 months of service, was evaluated. First, metrology was conducted to quantify head taper material loss and implant articular surface wear. Then, joint frictional moments for each retrieved head-and-cup pair were measured during 10 cycles of simulated physiological gait in a biomechanical model. Taper material loss was evaluated for correlations with frictional moments, articular wear, head diameter, head-cup clearance, and time in vivo.

RESULTS

Peak resultant frictional moments ranged from 9.1 to 26.3 Nm, averaging 17.3 ± 2.7 Nm. Fretting and corrosion damage during in vivo service resulted in material loss from the head tapers ranging between 0.04 and 25.57 mm3, compared with combined head and cup articular wear of 0.80 to 351.75 mm3 in this cohort. Taper material loss was not correlated with higher frictional moments (R = -0.20 to 0.11, p = 0.07 to 0.81). Higher frictional moments from axial rotation were correlated with higher head and cup wear (R = 0.33, p < 0.01). The correlation between taper material loss and head diameter was weak and did not reach statistical significance (R = 0.20, p = 0.07). Taper material loss was not correlated with nominal head-cup clearance (R = 0.06, p = 0.6). Finally, taper material loss increased significantly over time (R = 0.34, p < 0.01).

CONCLUSIONS

Despite serious concerns regarding trunnionosis, volumes of head taper wear were generally lower than those of articular surface wear. There was no statistical correlation between taper wear and frictional moments. Therefore, the results suggest that high friction in metal-on-metal implants does not contribute to higher material loss at the head taper, despite high bending moments.

CLINICAL RELEVANCE

The amount of metal debris and corrosion products from taper junctions of the joint arthroplasties, widely recognized as an insidious cause of failure, was not correlated with joint frictional moments. Multiple factors affect taper wear: implant design, material, size, surface finish, and patient weight and activity level. However, in the present cohort, high friction of metal-on-metal total hip replacements likely did not contribute to increased volume of material loss at taper interfaces, despite increased moments at the locations of taper material loss.

Origins of material loss in highly worn acetabular cups of metal-on-metal total hip replacements

Excessive wear has been one of the major failure modes of metal-on-metal hip implants. From a collection of 541 retrieved ASR metal-on-metal implants, we selected those head-cup pairs with combined wear >100 mm³ , (N = 42) to assess the distributions of wear volume on cups, and non-conformance in the worn areas at the head-cup interfaces. All 42 had severe cup edge wear (average maximum wear depth 500 μm). On average, 58% of wear volume of cups occurred at the edge areas, whereas 42% occurred well inside the socket, indicating that substantial wear volume of cups was generated well inside the socket. Particularly, in eight cups, more than half of the wear volume occurred well inside the socket. The head-cup conformance in the worn areas was deteriorated. On average, in worn areas, head-cup clearance was approximately eight times greater than in unworn areas, and the sphericity of heads and cups was approximately 36 times and 84 times higher, respectively, than in unworn areas. The radius of curvature of the worn surfaces of heads and cups varied widely, with an average variation of 3 mm (0.6-7 mm) and 11 mm (2-47 mm) for heads and cups, respectively. The severely deteriorated conformance at the edge areas and the areas well inside the socket, due to edge contact, could be the major factor for excessive wear of these 42 pairs. © 2018 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res.

Five Hundred Fifty-five Retrieved Metal-on-metal Hip Replacements of a Single Design Show a Wide Range of Wear, Surface Features, and Histopathologic Reactions

BACKGROUND

In 2010, a widely used metal-on-metal hip implant design was voluntarily recalled by the manufacturer because of higher than anticipated failure rates at 5 years. Although there was a large published range of revision rates, numerous studies had reported a higher risk of revision for excessive wear and associated adverse tissue reactions when compared with other metal-on-metal total hips. The reasons for this were suggested by some to be related to cup design features.

QUESTIONS/PURPOSES

From retrievals of ASR metal-on-metal implants and tissue samples obtained at revision surgery, we asked the following questions: (1) What were the common and uncommon surface features? (2) What were the common and uncommon linear and volumetric wear characteristics? (3) Were there common taper corrosion characteristics? (4) What aseptic lymphocytic vasculitis-associated lesion (ALVAL) features were present in the tissues?

METHODS

Five hundred fifty-five ASRs, including 23 resurfacings, were studied at one academic research center. Features of wear (eg, light and moderate scratching), damage (eg, deposits, gouges), and bone attachment on the porous coating were semiquantitatively ranked from 0 (none) to 3 (> 75%) based on the amount of a feature in each region of interest by the same experienced observer throughout the study. Visible features of head taper corrosion were ranked (Goldberg score) from 1 (none) to 4 (severe) by the same observer using a previously published scoring method. An experienced tribologist measured component wear depth using a coordinate measuring machine and quantified wear volume using previously validated methods. All available tissues were sampled and examined for features of ALVAL and scored from 0 to 10 by a single observer using a method they previously developed and published. A score from 0 to 4 is considered low, 5 to 8 is considered moderate, and 9 or 10 is considered high with regard to the risk of metal hypersensitivity features in the tissues.

RESULTS

The most common bearing surface features were light and moderate scratches and removal or postremoval damage. Discoloration and deposits were commonly observed on femoral heads (55% [305 of 553]) and less commonly on cups (30% [165 of 546]). There was no evidence of impingement or dislocation damage. There was typically a small amount of bone attachment in at least one of eight designated regions of interest (84% [460 of 546]); extensive or no bone attachment was uncommon. Edge wear was highly prevalent. The maximum wear of 469 cups (88%) occurred near the edge, whereas the maximum wear of 508 femoral heads (94%) occurred between the pole and 45° from the pole. The median combined head-cup wear volume was 14 mm (range, 1-636 mm). One hundred sixty-nine pairs (32%) had a combined wear volume of < 10 mm, 42 pairs (8%) had volumetric wear of > 100 mm, and 319 pairs (60%) had wear volume between 10 and 100 mm³. Seventy-four percent of tapers (390 of 530) received a Goldberg score of 4, 22% (116 of 530) a score of 3, < 5% (24 of 530) a score of 2, and none received a score of 1. The most frequent ALVAL score was 5 out of 10 (35 of 144 hips [24%]) and ranged from 2 (one hip) to 10 (nine hips); 92 of 144 (64%) had a moderate score, 17 of 144 (12%) had a high score, and 35 (24%) had a low score.

CONCLUSIONS

Although edge wear was prevalent, in most cases, this was not associated with high wear. The increased diameter and decreased coverage angle of the ASR design may have resulted in the observed high incidence of edge wear while perhaps decreasing the risk for impingement and dislocation.

CLINICAL RELEVANCE

The role of bearing wear in the revisions of metal-on-metal implants is controversial, because it is known that there is a large range of in vivo wear rates even within the same implant type and that patient variability affects local tissue responses to wear debris. The observations from our study of 555 retrieved ASR implant sets indicate that there was a wide range of wear including a subset with very high wear. The results suggested that the failure of the ASR and ASR XL was multifactorial, and the failure of different subgroups such as those with low wear may be the result of mechanisms other than reaction to wear debris.