Friction of composite cushion bearings for total knee joint replacements under adverse lubrication conditions

A lubrication replenishment theory for hydrogels

Hydrogels are suggested as less invasive alternatives to total joint replacements, but their inferior tribological performance compared to articular cartilage remains a barrier to implementation. Existing lubrication theories do not fully characterise the friction response of all hydrogels, and a better insight into the lubrication mechanisms must be established to enable optimised hydrogel performance. We therefore studied the lubricating conditions in a hydrogel contact using fluorescent imaging under simulated physiological sliding conditions. A reciprocating configuration was used to examine the effects of contact dimension and stroke length on the lubricant replenishment in the contact. The results show that the lubrication behaviour is strongly dependent on the contact configurations; When the system operates in a 'migrating' configuration, with the stroke length larger than the contact width, the contact is uniformly lubricated and shows low friction; When the contact is in an 'overlapping' configuration with a stroke length smaller than the contact width, the contact is not fully replenished, resulting in high friction. The mechanism of non-replenishment at small relative stroke length was also observed in a cartilage contact, indicating that the theory could be generalised to soft porous materials. The lubrication replenishment theory is important for the development of joint replacement materials, as most physiological joints operate under conditions of overlapping contact, meaning steady-state lubrication does not necessarily occur.

The effect of albumin and γ-globulin on synovial fluid lubrication: Implication for knee joint replacements

Total knee arthroplasty has become a routine procedure for patients suffering from joint diseases. Although the number of operations continuously increases, a limited service-life of implants represents a persisting challenge for scientists. Understanding of lubrication may help to suitably explain tribological processes on the way to replacements that become durable well into the third decade of service. The aim of the present study is to assess the formation of protein lubricating film in the knee implant. A developed knee simulator was used to observe the contact of real femoral and transparent polymer tibial component using fluorescent microscopy. The contact was lubricated by various protein solutions with attention to the behaviour of albumin and γ-globulin. In order to suitably mimic a human synovial fluid, hyaluronic acid and phospholipids were subsequently added to the solutions. Further, the change in shape and the migration of the contact zone were studied. The results showed considerable appearance differences of the contact over the swing phase of the simplified gait cycle. Regarding film formation, a strong interaction of the various molecules of synovial fluid was observed. It was found that the thickness of the lubricating layer stabilizes within around 50 s. Throughout the contact zone, protein agglomerations were present and could be clearly visualised using the applied optical technique.

Frictional characterization of injectable hyaluronic acids is more predictive of clinical outcomes than traditional rheological or viscoelastic characterization

Hyaluronic acid injections have been a mainstay of arthritis treatment for decades. However, much controversy remains about their clinical efficacy and their potential mechanism of action. This approach to arthritis therapy is often called viscosupplementation, a term which is rooted in the elevated viscosity of the injected solutions. This terminology also suggests a mechanical pathway of action and further implies that their efficacy is dependent on viscosity. Notably, previous studies of the relationship between viscous properties of hyaluronic acid solutions and their clinical efficacy have not been definitive. Recently we developed an experimental and analytical framework for studying cartilage lubrication that captures the Stribeck-like behavior of cartilage in an elastoviscous transition curve. Here we apply this framework to study the lubricating behavior of six hyaluronan products currently used for injectable arthritis therapy in the US. Despite the fact that the source and chemical modifications endow these products with a range of lubricating properties, we show that the lubricating effect of all of these materials can be described by this Stribeck-like elastoviscous transition. Fitting this data to the elastoviscous transition model enables the calculation of effective lubricating viscosities for each material, which differ substantially from the viscosities measured using standard rheometry. Further we show that while data from standard rheometry are poor predictors of clinical performance of these materials, measurements of friction coefficient and effective lubricating viscosity correlate well (R2 = 0.77; p < 0.005) with assessments of improved clinical function reported previously. This approach offers both a novel method that can be used to evaluate potential clinical efficacy of hyaluronic acid formulations and provide new insight on their mode of action.

The use of compliant layer prosthetic components in orthopedic joint repair and replacement: a review

The surgical repair or treatment of degenerative joint disease has traditionally involved the substitution of synthetic materials for one or both surfaces of the joint. Engineering thermoplastics, metals, and ceramics have either been widely accepted or experimentally evaluated for use as bearing surfaces in these prostheses. When engineering thermoplastics are used, the opposing surface is a metal or a ceramic, but metal-on-metal, metal-on-ceramic, and ceramic-on-ceramic have also been used or tested. Researchers have sought the opportunity to utilize materials with compressive mechanical properties more closely matching those of the natural articular cartilage. This review discusses the theory, testing, and application of elastomers for one bearing component of articular joint prostheses.

Future directions in knee replacement

The use of artificial joints for the treatment of osteoarthritis is expected to expand considerably over the next decade. While newer technologies can offer yet further improvements in total knee systems, implementation will be strongly affected by the need to satisfy apparently competing requirements. Patients expect quicker rehabilitation, improved performance, and lifelong durability; on the other hand, economic constraints require a reduction in cost for each procedure, as well as early intervention and preventative measures, while there is increased pressure from health care systems to use evidence-based medicine as the standard of choice for implants and techniques. The success of a knee replacement depends on the design itself, the surgical technique, the rehabilitation, and, not least, the patient. The major goal of the implant design can be redefined as a restoration of normal knee mechanics, whether by maximum preservation of tissues, or by guiding surfaces that replace their function. Surgical technique needs to be less invasive but achieve optimal patient-specific alignment and soft tissue balancing. Rehabilitation procedures must achieve the expectations of realistic patients. Testing and evaluation methods need to be upgraded for enhanced predictability. This paper discusses current trends and future possibilities to address this expansive scope of design criteria.

Accelerated aging, natural aging, and small punch testing of gamma-air sterilized polycarbonate urethane acetabular components

The objectives of this study were three-fold: (1) to determine the applicability of the small punch test to characterize Bionate 80A polycarbonate urethane (PCU) acetabular implants; (2) to evaluate the susceptibility of PCU acetabular implants to exhibit degradation of mechanical behavior following gamma irradiation in air and accelerated aging; and (3) to compare the oxidation of gamma-air sterilized PCU following accelerated aging and 5 years of natural shelf aging. In addition to attenuated total reflectance-Fourier transform infrared spectroscopy, we also adapted a miniature specimen mechanical test, the small punch test, for the deformable PCU cups. Accelerated aging was performed using ASTM F2003, a standard test that represents a severe oxidative challenge. The results of this study suggest that the small punch test is sufficiently sensitive and reproducible to discriminate slight differences in the large-deformation mechanical behavior of Bionate 80A following accelerated aging. The gamma-air sterilized PCU had a reduction of 9% in ultimate load after aging. Five years of shelf aging had little effect on the mechanical properties of the PCU. Overall, our findings suggest that the Bionate 80A material has greater oxidative stability than ultra-high molecular weight polyethylene following gamma irradiation in air and exposure to a severe oxidative challenge.

Compliant-layer tibial bearing inserts: Friction testing of different materials and designs for a new generation of prostheses that mimic the natural joint

Total joint replacements (TJRs) have a limited lifetime, but the introduction of devices that exhibit good lubricating properties with low friction and low wear could well extend this. A novel tibial bearing design, using polyurethane (PU) as a compliant layer, to mimic the natural joint, has been developed. To determine accurately the mode of lubrication under which these joints operate, a synthetic lubricant was used in all these tests. Friction tests were carried out to assess the effects of material modulus and surface roughness, together with bearing design parameters such as bearing thickness and conformity, on lubrication. Corethane 80A was the preferred material and was chosen as the compliant layer for subsequent testing. A low surface roughness resulted in lower asperity contact as the asperities were depressed by the pressurized entraining fluid and full-fluid-film lubrication was approached. The three different tibial bearing conformities (low, medium, and high) did not appear to influence the mode of lubrication and all these bearings performed with extremely low friction. Similarly, the bearing thickness effects on lubrication at the levels tested (2 mm, 3 mm, and 4 mm) were minimal, although the effects of layer thickness on interface shear stress could be expected to be significant. This study describes a series of friction tests that have been used to select the most appropriate material and to optimize the design parameters to establish optimum conditions for these compliant layer joints.

Compliant layer bearings in artificial joints. Part 2: Simulator and fatigue testing to assess the durability of the interface between an elastomeric layer and a rigid substrate

Artificial joints have been much improved since their introduction but they still have a limited lifetime. In an attempt to increase their life by improving the lubrication acting within these prostheses, compliant layered polyurethane (PU) joints have been devised. These joints mimic the natural synovial joint more closely by promoting fluid film lubrication. In this study, tests were performed on compliant layer joints to determine their ability to function under a range of conditions. Both static and dynamic compression tests were undertaken on compliant artificial hip joints of two different radial clearances. Friction tests were also performed before and after static loading. In addition to this, knee wear tests were conducted to determine the suitability of a compliant layer in these applications. In the knee tests, variations in experimental testing conditions were investigated using both active and passive rotation and severe malalignment of the tibial inserts. The static compression tests together with the friction studies suggest that a small radial clearance is likely to result in ‘grabbing’ contact between the head and cup. The larger radial clearance (0.33 μm) did not exhibit these problems. The importance of the design of the compliant layer joints was highlighted with delamination occurring on the lateral bearings during the knee wear studies. The bearings with a layer 2 mm thick performed better than the bearings with a layer 3 mm thick. Tests conducted on flat PU bearings resulted in no delamination; therefore, it was concluded that the layer separation was caused by design issues rather than by material issues. It was found that, with careful material choice, consideration of design, and effective manufacturing techniques, the compliant layer joint functioned well and demonstrated durability of the union between the hard and soft layers. These results give encouragement for the suitability of these joints for clinical use.

Compliant layer bearings in artificial joints. Part 1: The effects of different manufacturing techniques on the interface strength between an elastomeric layer and a rigid substrate

The premise that elastomeric materials could be used as one or more of the articulating components in both hip and knee prostheses was postulated first by Unsworth and co-workers. It was thought that such materials might have the capacity to mimic natural joint behaviour more closely than the more rigid bearing surfaces commonly in use. A more natural joint function in artificial joints should promote better tribology, with full fluid-film lubrication being the goal. Early tests showed that this objective could potentially be achieved with a judicious choice of materials and carefully controlled manufacturing techniques. This paper (Part 1 of a two-part series) describes and explains the techniques used to verify the material selection as well as to determine the most appropriate manufacturing procedure to obtain a strong and robust interface between the support and bearing material of the prosthesis. Two polycarbonate urethane (PU) materials with different hardness values (Corethane 80A and Corethane 75D) gave sufficient interfacial strength when moulded under optimum conditions. Corethane 80A was used as the soft bearing material while Corethane 75D provided the rigid backing component. Peel tests revealed strong interface bonds, varying with processing conditions between 350 and 862 N. Fourier transform infrared spectroscopy and micro-thermal analysis showed that a fusion bond over 30 μm thick formed at the interface. The results of the range of tests and analyses, which have been used in this study, have provided sufficient evidence to validate the process used to manufacture these components.

Compliant layer acetabular cups: friction testing of a range of materials and designs for a new generation of prosthesis that mimics the natural joint

Total joint replacements (TJRs) have a limited lifetime, but the introduction of components that exhibit good lubricating properties with low friction and low wear could extend the life of TJRs. A novel acetabular cup design using polyurethane (PU) as a compliant layer (to mimic the natural joint) has been developed. This study describes a series of friction tests that have been used to select the most appropriate material, optimize the design parameters, and fine-tune the manufacturing processes of these joints. To determine accurately the mode of lubrication under which these joints operate, a synthetic lubricant was used in all these tests. Friction tests were carried out to assess the lubrication of four PU bearing materials. Corethane 80A was the preferred material and was subjected to subsequent testing. Friction tests conducted on acetabular cups, manufactured using Corethane 80A articulating against standard, commercially available femoral heads, demonstrated friction factors approaching those for full-fluid-film lubrication with only approximately 1 per cent asperity contact. As the joint produces these low friction factors within less than half a walking cycle after prolonged periods of loading, start-up friction was not considered to be a critical factor. Cups performed well across the full range of femoral head sizes, but a number of samples manufactured with reduced radial clearances performed with higher than expected friction. This was caused by the femoral head being gripped around the equator by the low clearance cup. To avoid this, the cup design was modified by increasing the flare at the rim. In addition to this the radial clearance was increased. As the material is incompressible, a radial clearance of 0.08 mm was too small for a cup diameter of 32 mm. A clearance of between 0.10 and 0.25 mm produced a performance approaching full-fluid-film lubrication. This series of tests acted as a step towards the optimization of the design of these joints, which has now led to an in vivo ovine model.

Design aspects of compliant, soft layer bearings for an experimental hip prosthesis

Currently, an artificial hip joint can be expected to last, on average, in excess of 15 years with failure due, in the majority of cases, to late aseptic loosening of the acetabular component. A realistic alternative to the problem of wear in conventional joints is the introduction of bearing surfaces that exhibit low wear and operate in the full fluid-film lubrication regime. Contact analyses and friction tests were performed on compliant layer joints (metal-on-polyurethane) and the design of a prototype ovine arthroplasty model was investigated. When optimized, these components have been shown to achieve full fluid-film lubrication.

The effect of bone cement particles on the friction of polyethylene and polyurethane knee bearings

Compliant layer knee joints have been considered for use in an attempt to increase the serviceable life of artificial joints. If designed correctly, these joints should operate within the full-fluid film lubrication regime. However, adverse tribological conditions, such as the presence of bone and bone cement particles, may breach the fluid film and cause surface wear. The frictional behaviour of both polyurethane (PU) and conventional polyethylene (PE) tibial components against a metallic femoral component was therefore assessed when bone cement particles were introduced into the lubricant. The bone cement particles caused a large increase in the frictional torque of both the PE and PU bearings; however, the friction produced by the PU bearings was still considerably lower than that produced by the PE bearings. The volume of bone cement particles between each of the bearings and the resultant frictional torque both decreased over time. This occurred more quickly with the PE bearings but greater damage was caused to the surface of the PE bearings than the PU components.

Theoretical investigation of an artificial joint with micro-pocket-covered component and biphasic cartilage on the opposite articulating surface

This paper presents a theoretical investigation of a geometrically idealized artificial joint with micro-pocket-covered component and biphasic cartilage on the opposite articulating surface. The fluid that exudes from the biphasic cartilage fills and pressurizes the micro-pockets. In this way, a poro-elasto-hydrodynamic regime of lubrication is developed. Assuming that lower friction would result in lower adhesive wear, and neglecting the fatigue as well as the abrasive wear, the proposed bearing system hypothetically could reduce the amount of wear debris. Equations of the linear biphasic theory are applied for the confined and unconfined compression of the cartilage. The fluid pressure and the elastic deformation of the biphasic cartilage are explicitly presented. The effective and equilibrium friction coefficients are obtained for the particular configuration of this bearing system. The micro-pockets geometrical parameters (depth, radius, surface distribution and edge radius) must be established to reduce the local contact stresses, to assure low friction forces and to minimize the biphasic cartilage damage. The influence of the applied pressure, porosity of the micro-pocket-covered component, filling time, cartilage elasticity, permeability and porosity upon the micro-pockets depth is illustrated. Our results are based upon the previously published data for a biphasic cartilage.

Elastohydrodynamic lubrication analysis of a functionally graded layered bearing surface, with particular reference to 'cushion form bearings' for artificial knee joints

Elastohydrodynamic lubrication of a functionally graded layered (FGL) bearing surface, whose elastic modulus increases with depth from the bearing surface, was investigated in this study. The finite difference method was employed to solve the Reynolds equation, simultaneously with the elasticity equation of the bearing surface, under circular point contacts. The finite element method was adopted to solve the elasticity equation for the FGL bearing surface. The displacement coefficients thus obtained were used to calculate the elastic deformation of the bearing surface, required for the elastohydrodynamic lubrication analysis. Good agreement of the predicted film thickness and pressure distribution was obtained, between the present method and a previous study for a single layered bearing surface with a uniform elastic modulus. The general numerical methodology was then applied to an FGL bearing surface with both linear and exponential variations in elastic modulus, with particular reference to the 'cushion form bearing' for artificial knee joints. The predicted film thickness and pressure distribution were shown to be quite close to those obtained for a single layer under typical operating conditions representative of artificial knee joints, provided that the elastic modulus of the single layer was chosen to be the average elastic modulus of the graded layer.

Utilization of moiré interferometry to study the strain distribution within multi-layer thermoplastic elastomers

The use of soft elastomeric cushion form bearings as an alternative material to ultra-high molecular weight polyethylene (UHMWPE) has been proposed in the literature as providing enhanced lubrication and lower friction. However, the abrupt change in stiffness between the bearing's soft contact layer and its rigid support substrate results in high shear stresses and leads to the debonding of the soft layer from the substrate. The use of functionally modulus-graded material has been proposed as a solution to this problem. This paper investigates the use of moiré interferometry to study the strain distribution within and across the interfaces of multi-layer elastomeric samples, which were fabricated as models for functionally modulus-graded materials. While this technique has been widely used to study the strain distribution in rigid materials and composites, this paper represents the first report of its application to low-modulus polymers at temperatures where they exhibit significant viscoelastic behavior. The results presented clearly demonstrate that the moiré interferometry technique can be successfully applied in the field of low-modulus elastomeric materials. The analysis of the moiré patterns suggests that the soft elastomeric material under the contact point was subjected to a compressive epsilonx, and was pushed sideways. The analysis also showed that the maximum shear strain occurred where the deformation was constrained, which could possibly lead to a local fatigue failure in the sample.

Prediction of transient lubricating film thickness in knee prostheses with compliant layers

The transient lubricating film thickness in knee prostheses using compliant layers has been predicted under simulated walking conditions based upon the elastohydrodynamic lubrication theory. Qualitative agreement has been found between the present theoretical predictions and the experimental measurements using an electric resistance technique reported earlier. It has been shown that the contact geometry plays an important role in the generation of fluid film lubrication in knee prostheses using compliant layers. The maximum lubricating film thickness is predicted for the maximized contact area of a transverse conjunction where the semi-minor contact radius lies in the direction of entraining. The additional advantage of the transverse contact conjunction is that the possibility of lubricant starvation due to small stroke length can be minimized. All these factors, together with the kinematic requirements in the natural knee joint, should be taken into consideration when designing artificial knee joint replacements.