Wear of Artificial Joint Materials IV

Impact of Structural Compliance of a Six Degree of Freedom Joint Simulator on Virtual Ligament Force Calculation in Total Knee Endoprosthesis Testing

The AMTI VIVO™ six degree of freedom joint simulator allows reproducible preclinical testing of joint endoprostheses under specific kinematic and loading conditions. When testing total knee endoprosthesis, the articulating femoral and tibial components are each mounted on an actuator with two and four degrees of freedom, respectively. To approximate realistic physiological conditions with respect to soft tissues, the joint simulator features an integrated virtual ligament model that calculates the restoring forces of the ligament apparatus to be applied by the actuators. During joint motion, the locations of the ligament insertion points are calculated depending on both actuators' coordinates. In the present study, we demonstrate that unintended elastic deformations of the actuators due to the specifically high contact forces in the artificial knee joint have a considerable impact on the calculated ligament forces. This study aims to investigate the effect of this structural compliance on experimental results. While the built-in algorithm for calculating the ligament forces cannot be altered by the user, a reduction of the ligament force deviations due to the elastic deformations could be achieved by preloading the articulating implant components in the reference configuration. As a proof of concept, a knee flexion motion with varying ligament conditions was simulated on the VIVO simulator and compared to data derived from a musculoskeletal multibody model of a total knee endoprosthesis.

Influence of hip joint simulator design and mechanics on the wear and creep of metal-on-polyethylene bearings

Hip joint simulators are used extensively for preclinical testing of hip replacements. The variation in simulator design and test conditions used worldwide can affect the tribological performance of polyethylene. The aim of this study was to assess the effects of simulator mechanics and design on the wear and creep of ultra-high-molecular-weight polyethylene. In the first part of this study, an electromechanical simulator and pneumatic simulator were used to compare the wear and creep of metal-on-polyethylene components under the same standard gait conditions. In the second part of the study, the same electromechanical hip joint simulator was used to investigate the influence of kinematics on wear. Higher wear rates and penetration depths were observed from the electromechanical simulator compared with the pneumatic simulator. When adduction/abduction was introduced to the gait cycle, there was no significant difference in wear with that obtained under the gait cycle condition without adduction/abduction. This study confirmed the influence of hip simulator design and loading conditions on the wear of polyethylene, and therefore direct comparisons of absolute wear rates between different hip joint simulators should be avoided. This study also confirmed that the resulting wear path was the governing factor in obtaining clinically relevant wear rates, and this can be achieved with either two axes or three axes of rotations. However, three axes of rotation (with the inclusion of adduction/abduction) more closely replicate clinical conditions and should therefore be the design approach for newly developed hip joint simulators used for preclinical testing.

Effect of motion inputs on the wear prediction of artificial hip joints

Hip joint simulators have been largely used to assess the wear performance of joint implants. Due to the complexity of joint movement, the motion mechanism adopted in simulators varies. The motion condition is particularly important for ultra-high molecular weight polyethylene (UHMWPE) since polyethylene wear can be substantially increased by the bearing cross-shear motion. Computational wear modelling has been improved recently for the conventional UHMWPE used in total hip joint replacements. A new polyethylene wear law is an explicit function of the contact area of the bearing and the sliding distance, and the effect of multidirectional motion on wear has been quantified by a factor, cross-shear ratio. In this study, the full simulated walking cycle condition based on a walking measurement and two simplified motions, including the ISO standard motion and a simplified ProSim hip simulator motion, were considered as the inputs for wear modelling based on the improved wear model. Both the full simulation and simplified motions generated the comparable multidirectional motion required to reproduce the physiological wear of the bearing in vivo. The predicted volumetric wear of the ProSim simulator motion and the ISO motion conditions for the walking cycle were 13% and 4% lower, respectively, than that of the measured walking condition. The maximum linear wear depths were almost the same, and the areas of the wear depth distribution were 13% and 7% lower for the ProSim simulator and the ISO condition, respectively, compared with that of the measured walking cycle motion condition.

The wear of metal-on-metal total hip prostheses measured in a hip simulator

New generation metal-on-metal prostheses have been introduced to try and overcome the problem of osteolysis often attributed to the wear particles of the polyethylene component of conventional metal-on-ultra-high molecular weight polyethylene (UHMWPE) joints. The wear rates of four metal-on-metal joints (two different clearances) were assessed along with that of a conventional metal-on-UHMWPE joint. Friction measurements of the metal-on-metal joints were taken before and after the wear test and compared. Two distinct wear phases were discernible for all the metal-on-metal joints: an initial wear phase up to 0.5 x 10(6) cycles and then a lower steady state wear phase. The steady state wear rate of the 22 microm radial clearance metal-on-metal joint was lower than that for the 40 microm radial clearance joint, although this difference was not found to be significant (p > 0.15). The wear rates for all the joints tested were consistent with other simulator studies. The friction factors produced by each joint were found to decrease significantly after wear testing (p < 0.05).

Evaluation of a hip joint simulator

To evaluate the functioning of the Durham hip joint wear simulator, the wear rates of ultra high molecular weight polyethylene (UHMWPE) and polytetrafluoroethylene (PTFE) acetabular cups articulating against 22 mm diameter cobalt-chromium-molybdenum (CoCrMo) femoral heads were studied. A wear test was conducted in a lubricant of distilled water at 37 degrees C for a duration of 4.8 million cycles. The average penetration rate for the CoCrMo femoral heads against UHMWPE acetabular cups was 0.03 mm/10(6) cycles, while penetration rate for PTFE cups was some twenty times greater. These results are of a similar order of magnitude to other simulator studies in distilled water and are in a similar ratio to clinical data.

A comparison between gravimetric and volumetric techniques of wear measurement of UHMWPE acetabular cups against zirconia and cobalt-chromium-molybdenum femoral heads in a hip simulator

Five cobalt-chromium-molybdenum (CoCrMo) and five zirconia femoral head components have been wear tested against 28 mm diameter ultra high molecular weight polyethylene (UHMWPE) acetabular cups for 5 million cycles in the Durham hip joint wear simulator using bovine serum as a lubricant. Wear measurements used gravimetric and volumetric techniques and no statistically significant difference was found between the measurement methods. The wear rates of the acetabular cups against both femoral heads are presented for both measurement methods. The UHMWPE acetabular cups showed a statistically significant higher linear wear rate for the first 2 million cycles than the lower linear wear rate from 2 million cycles to the end of the test, against both femoral head materials. Over the full duration of the wear test, the wear rates of acetabular cups articulating against zirconia femoral heads were lower than against CoCrMo femoral heads. The wear rates up to 2 million cycles and from 2 to 5 million cycles for both femoral head materials were consistent with other studies.

A hip joint simulator study using simplified loading and motion cycles generating physiological wear paths and rates

In some designs of hip joint simulator the cost of building a highly complex machine has been offset with the requirement for a large number of test stations. The application of the wear results generated by these machines depends on their ability to reproduce physiological wear rates and processes. In this study a hip joint simulator has been shown to reproduce physiological wear using only one load vector and two degrees of motion with simplified input cycles. The actual path of points on the femoral head relative to the acetabular cup were calculated and compared for physiological and simplified input cycles. The in vitro wear rates were found to be highly dependent on the shape of these paths and similarities could be drawn between the shape of the physiological paths and the simplified elliptical paths.

Kinematics of the MATCO hip simulator and issues related to wear testing of metal-metal implants

Metal-metal hip implants have been used clinically in Europe to reduce the risk of wear particle induced osteolysis. Joint simulator devices could provide useful information for design improvement of the modern generation of metal-metal hip implants. Early wear results for metal-metal hip specimens were obtained using a MATCO hip simulator. A detailed kinematic analysis was developed for the MATCO simulator and applied to two of the wear experiments to predict the starting surface motion, contact zone and lubricant film thickness. It was shown that points on cup surfaces were not subjected to a reciprocating interaction with the head during wear at the beginning of testing but as wear proceeded, it was suggested that, in some cases, reciprocating interaction did occur on the cup surface. Comparison between simulator and in vivo kinematics suggested a more realistic representation for cup than for head wear. In the simulator, the Hertzian contact zone moved in a circular path over the cup surface and changed in size in correspondence with the applied load. Elastohydrodynamic lubrication was considered to be possible in the simulator, with estimated fluid film thickness as great as 0.1 micron. However, such thick films were not likely to have occurred at the start of the two wear tests which were examined in detail, although some mixed film lubrication might have accounted for the relatively low wear of one of the specimens. The inclusion of kinematic details, contact mechanics and elastohydrodynamic lubrication analysis in simulator testing protocols and in design of metal metal hip implants was recommended.

Charnley wear model for validation of hip simulators--ball diameter versus polytetrafluoroethylene and polyethylene wear

Wear rates of polytetrafluoroethylene (PTFE) and polyethylene cups were compared in 9-channel and 12-channel simulators, using serum lubrication and gravimetric techniques for wear assessment. Cobalt-chromium (CoCr) and alumina ceramic femoral heads in 22-42 mm diameter range were used to validate simulator wear rates against clinical data. This was also the first study of three femoral head sizes evaluated concurrently in a simulator (with three replicate specimens) and also the first report in which any wear experiments were repeated. Fluid absorption artefacts were within +/-1 per cent of wear magnitude for PTFE and +/-8 per cent for polyethylene and were corrected for. Wear rates were linear as a function of test duration. Precision within each set of three cups was within +/-6 per cent. The wear rates from experiments repeated over 15 months were reproducible to within +/-24 per cent. However, the magnitudes of the simulator wear rates were not clinically accurate, the PTFE wear rates (2843 mm3/10(6) cycles; 22 mm diameter) were over three times higher than in vivo, the polyethylene 30 to 50 per cent on the low side (23 mm3/10(6) cycles; 22 mm diameter). Volumetric wear rate increased with respect to size of femoral head and a linearly increasing relationship of 7 8 per cent/mm was evident with respect to femoral head diameter for both PTFE and polyethylene. These data compared well with the clinical data.

Discussion on the design of a hip joint simulator

Hip joint simulators were developed for predicting, by attempting to duplicate in vitro physiological loads and motion, the wear rate that total hip replacements are likely to show in vivo. From a theoretical point of view, loading and motion cycles of hip joints could be closely reproduced by three rotation actuators and three force actuators. However existing devices have been designed assuming that some of these degrees of freedom are negligible, in order to reduce the complexity of the equipment. The present study singles out some preliminary indications on the design choices regarding the spatial configuration of loading and motion actuators. The aim is to define theoretically a simplified simulator but still able to apply the most physiologically realistic loading cycle to the specimen.

Wear of polyethylene acetabular cups against alumina femoral heads. 5 prostheses compared in a hip simulator for 35 million walking cycles

5 ultra-high molecular weight polyethylene acetabular cups articulated against alumina femoral heads for 35 million walking cycles in a hip joint simulator designed for wear tests of total hip prostheses. The specimens were from Protek, Biomet, Link, Howmedica and Thackray. In the Howmedica specimen, the wear was zero, and in Link and Thackray practically negligible. In Biomet, however, the wear was noteworthy and in Protek disastrous after 20 million cycles because in these 2 prostheses the head was attached to a titanium-alloy stem by taper-fit: titanium-alloy particles that were removed from the taper because of micromotion between the head and stem were entrapped between the head and cup, adhering to the head and making it rough, which led to severe abrasive wear of the Protek cup. It was worn through at 26 million cycles, the total wear being 3,170 mg. In Biomet, Link and Thackray, the total wear was 124, 5.3 and 17.6 mg, respectively. Polyethylene wear particles may lead to adverse tissue reactions and eventual loosening of the implant. The results indicate that by the use of alumina heads, polyethylene wear can be eliminated, but this advantage may be lost if the head is attached to a titanium-alloy taper.

Design considerations for cushion form bearings in artificial hip joints

Lubrication mechanisms and contact mechanics have been analysed in a new generation of 'cushion form' bearings for artificial hip joints, which comprise low elastic modulus layers on the articulating surfaces. Comparisons have been made with 'hard' bearings used in existing prostheses and also with the natural hip joint. Lubricating film thicknesses are enhanced by larger contact areas and lower contact pressures. For a fixed contact area, simultaneous changes in layer thickness and radial clearance have been shown to have a small effect on elastohydrodynamic film thickness. Hard bearings designed with the same contact area as the cushion bearings produced a similar film thickness, but lubricant film thickness is not optimized in current designs. The main advantage of using a cushion bearing with low elastic modulus layers was found to be associated with microelastohydrodynamic lubrication. Careful selection of the elastic modulus is important in order to ensure that this lubrication regime was effective. Low elastic modulus layers may also produce local deformations, which enhance squeeze film action. The elastic modulus of the material should not be lower than necessary to produce effective microelastohydrodynamic lubrication, as a further reduction in modulus only increases the strain distribution in the material. A lubricant film thickness of 0.3 microns has been predicted for a cushion hip prosthesis with a femoral head diameter of 32 mm and radius of contact zone of 16 mm, using a 2 mm thick layer with an elastic modulus of 20 MPa.

Tribology of total artificial joints

The tribology of total artificial replacement joints is reviewed. The majority of prosthesis currently implanted comprise a hard metallic component which articulates on ultra high molecular weight polyethylene surface. These relatively hard bearing surfaces operate with a mixed or boundary lubrication regime, which results in wear and wear debris from the ultra high molecular weight polyethylene surface. This debris can contribute to loosening and ultimate failure of the prostheses. The tribological performance of these joints has been considered and a number of factors which may contribute to increased wear rates have been identified. Cushion bearing surfaces consisting of low elastic modulus materials which can articulate with full fluid film lubrication are also described. These bearing surfaces have shown the potential for greatly reducing wear debris.

Ceramic bearing surfaces in total artificial joints: resistance to third body wear damage from bone cement particles

Studies of explanted Charnley hip prostheses have shown damage or scratching of the polished stainless steel femoral heads. This surface damage is probably due to third body wear by bone cement particles. Damaged femoral heads will produce increased wear rates of ultra high molecular weight polyethylene (UHMWPE) acetabular cups. Sliding wear tests carried out in the laboratory have shown that alumina ceramic counterfaces are more resistant to third body damage from bone cement particles than stainless steel counterfaces. The use of the ceramic femoral heads in artificial hip joints will help to preserve the smooth surface finish on the femoral bearing surface, which is necessary to ensure low wear rates of the UHMWPE cup throughout the lifetime of the prosthesis.

The influence of bone and bone cement debris on counterface roughness in sliding wear tests of ultra-high molecular weight polyethylene on stainless steel

Studies of explanted hip prostheses have shown high wear rates of ultra-high molecular weight polyethylene (UHMWPE) acetabular cups and roughening of the surface of the metallic femoral head. Bone and bone cement particles have also been found in the articulating surfaces of some joints. It has been proposed that bone or bone cement particles may cause scratching and deterioration in the surface finish of metallic femoral heads, thus producing increased wear rates and excessive amounts of wear debris. Sliding wear tests of UHMWPE pins on stainless steel have been performed with particles of different types of bone and bone cement added. Damage to the stainless steel counterface and the motion of particles through the interface have been studied. Particles of bone cement with zirconium and barium sulphate additives and particles of cortical bone scratched the stainless steel counterface. The cement particles with zirconium additive produced significantly greater surface damage. The number of particles entering the contact and embedding in the UHMWPE pin was dependent on particle size and geometry, surface roughness and contact stress. Particles are likely to cause surface roughening and increased wear rates in artificial joints.

Design and development of a versatile hip joint simulator and a preliminary assessment of wear and creep in Charnley total replacement hip joints

This paper describes the design of a new 3-station hip joint simulator and briefly discusses early results.

Fluid-sorption phenomena in sterilized polyethylene acetabular prostheses

The weight changes due to fluid-sorption were measured in 62 radiation-sterilized acetabular sockets and 10 unsterilized discs. The materials included two types of ultra-high molecular weight (UHMW) polyethylene (RCH 1000; Hi-Fax 1900) and a carbon-fibre-reinforced polyethylene (CFPE). The fluid absorption curve was consistently biphasic. In the first 30 d soak-period (Phase 1), the initial rate of fluid absorption averaged 153 micrograms/d for conventional UHMW polyethylene and 278 micrograms/d for carbon-fibre-reinforced polyethylene. In Phase 2, beyond 30 d and up to 400 d, fluid absorption reduced to linear rates of 27 micrograms/d for UHMW polyethylene and 43 micrograms/d for CFPE. The latter soak-weight-gain values corresponded to only 0.00016%/d and 0.00034%/d respectively. There was little difference in absorption rates between sterilized and unsterilized samples. However soak rates were generally higher in water compared to serum.