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

A Geometric Analysis of Polyethylene Liners Exposed to Acrylic-based Bone Cement

Background

Acrylic-based bone cement (polymethyl methacrylate [PMMA]) is a material commonly used in orthopaedic surgeries; however, during PMMA polymerization, a highly exothermic reaction occurs. The heat released in polymerization can damage nearby materials including poorly heat-resistant cross-linked polyethylene (XLPE). Both PMMA and XLPE are used in total hip arthroplasty and could interact during femoral stem fixation. We sought to determine if the exothermic polymerization of PMMA could alter the surface characteristics of XLPE acetabular liners.

Methods

Six XLPE liners were assigned to one of 4 experimental categories with varying volumes of PMMA applied in a manner that mimicked how the 2 materials would come into contact intraoperatively. Measurements were taken both pre- and post-intervention using a coordinate measuring machine for geometric and gravimetric analysis. Light microscopy was conducted postintervention to examine the surface for damage.

Results

Coordinate measuring machine measurements showed minimal gross deformation in all 6 liners, but there were isolated surface deposits in 4 of 6 liners. The average maximal surface deviations, when compared to the control, for liners exposed to 1 cc of cement, 2 cc of cement, or 1 cc of cement with a femoral head implant attached were 26.6 μm, 77.2 μm, and 26.4 μm, respectively. All but one liner showed an increase in volume following intervention when compared to the control. Subtle scratches were identified using light microscopy on all 6 liners.

Conclusions

XLPE shows areas of isolated surface deformation in a dose-dependent manner but with minimal gross deformation after interacting with highly exothermic PMMA.

Third body damage and wear in arthroplasty bearing materials: A review of laboratory methods

Third body wear of arthroplasty bearing materials can occur when hard particles such as bone, bone cement or metal particles become trapped between the articulating surfaces. This can accelerate overall implant wear, potentially leading to early failure. With the development of novel bearing materials and coatings, there is a need to develop and standardise test methods which reflect third body damage seen on retrieved implants. Many different protocols and approaches have been developed to replicate third body wear in the laboratory but there is currently no consensus as to the optimal method for simulating this wear mode, hence the need to better understand existing methods. The aim of this study was to review published methods for experimental simulation of third body wear of arthroplasty bearing materials, to discuss the advantages and limitations of different approaches, the variables to be considered when designing a method and to highlight gaps in the current literature. The methods were divided into those which introduced abrasive particles into the articulating surfaces of the joint and those whereby third body damage is created directly to the articulating surfaces. However, it was found that there are a number of parameters, for example the influence of particle size on wear, which are not yet fully understood. The study concluded that the chosen method or combination of methods used should primarily be informed by the research question to be answered and risk analysis of the device.

The influence of a calcium sulphate bone void filler on the third-body damage and polyethylene wear of total knee arthroplasty

OBJECTIVES

Bone void fillers are increasingly being used for dead space management in arthroplasty revision surgery. The aim of this study was to investigate the influence of calcium sulphate bone void filler (CS-BVF) on the damage and wear of total knee arthroplasty using experimental wear simulation.

METHODS

A total of 18 fixed-bearing U2 total knee arthroplasty system implants (United Orthopedic Corp., Hsinchu, Taiwan) were used. Implants challenged with CS-BVF were compared with new implants (negative controls) and those intentionally scratched with a diamond stylus (positive controls) representative of severe surface damage (n = 6 for each experimental group). Three million cycles (MC) of experimental simulation were carried out to simulate a walking gait cycle. Wear of the ultra-high-molecular-weight polyethylene (UHMWPE) tibial inserts was measured gravimetrically, and damage to articulating surfaces was assessed using profilometry.

RESULTS

There was no significant difference (p  >  0.05) between the wear rate of implants challenged with CS-BVF (3.3 mm3/MC (95% confidence interval (CI) 1.8 to 4.8)) and the wear rate of those not challenged (2.8 mm3/MC (95% CI 1.3 to 4.3)). However, scratching the cobalt-chrome (CoCr) significantly (p < 0.001) increased the wear rate (20.6 mm3/MC (95% CI 15.5 to 25.7)). The mean surface roughness of implants challenged with CS-BVF was equivalent to negative controls both after damage simulation (p = 0.98) and at the conclusion of the study (p = 0.28).

CONCLUSION

When used close to articulating surfaces, a low-hardness, high-purity CS-BVF had no influence on wear. When trapped between the articulating surfaces of a total knee arthroplasty, CS-BVF did not scratch the surface of CoCr femoral components, nor did it increase the wear of UHMWPE tibial inserts compared with undamaged negative controls.Cite this article: R. M. Cowie, S. S. Aiken, J. J. Cooper, L. M. Jennings. The influence of a calcium sulphate bone void filler on the third-body damage and polyethylene wear of total knee arthroplasty. Bone Joint Res 2019;8:65-72. DOI: 10.1302/2046-3758.82.BJR-2018-0146.R1.

Assessment of Titanium Alloy on Polyethylene Bearing Surfaces in Retrieved Uncemented Total Hip Replacements

Changes to the bearing surfaces of eighteen uncemented total hip replacements retrieved at revision surgery were assessed by three-dimensional binocular microscopy, Rank Taylor Hobson talysurf measurements, scanning electron microscopy, and X-ray dispersive analysis. Abrasions on the non-articular surface of the polyethylene cups were present. Bone particles were found in tracks in the bearing surfaces of both the titanium femoral heads and the polyethylene cups and were responsible for wear of these surfaces. Although the wear of the femoral heads appeared substantial to naked eye examination, the surface finish of these surfaces remained within the British ISO standards for titanium alloy when assessed by the methods used above. This study concluded that direct contact between polyethylene and bone should be avoided in total hip arthroplasty and that ‘third body’ wear from bone particles occurred in these uncemented prostheses. Both components of this type of implant should be replaced at revision surgery and titanium should be avoided as a bearing surface in hip arthroplasty. Present methods of assessing the surface finish of titanium should be re-evaluated and more reliable ones considered.

Influence of third-body particles originating from bone void fillers on the wear of ultra-high-molecular-weight polyethylene

Calcium sulfate bone void fillers are increasingly being used for dead space management in infected arthroplasty revision surgery. The presence of these materials as loose beads close to the bearing surfaces of joint replacements gives the potential for them to enter the joint becoming trapped between the articulating surfaces; the resulting damage to cobalt chrome counterfaces and the subsequent wear of ultra-high-molecular-weight polyethylene is unknown. In this study, third-body damage to cobalt chrome counterfaces was simulated using particles of the calcium sulfate bone void fillers Stimulan^® (Biocomposites Ltd., Keele, UK) and Osteoset^® (Wright Medical Technology, TN, USA) using a bespoke rig. Scratches on the cobalt chrome plates were quantified in terms of their density and mean lip height, and the damage caused by the bone void fillers was compared to that caused by particles of SmartSet GMV PMMA bone cement (DePuy Synthes, IN, USA). The surface damage from Stimulan^® was below the resolution of the analysis technique used; SmartSet GMV caused 0.19 scratches/mm with a mean lip height of 0.03 µm; Osteoset^® led to a significantly higher number (1.62 scratches/mm) of scratches with a higher mean lip height (0.04 µm). Wear tests of ultra-high-molecular-weight polyethylene were carried out in a six-station multi-axial pin on plate reciprocating rig against the damaged plates and compared to negative (highly polished) and positive control plates damaged with a diamond stylus (2 µm lip height). The wear of ultra-high-molecular-weight polyethylene was shown to be similar against the negative control plates and those damaged with third-body particles; there was a significantly higher (p < 0.001) rate of ultra-high-molecular-weight polyethylene wear against the positive control plates. This study showed that bone void fillers of similar composition can cause varying damage to cobalt chrome counterfaces. However, the lip heights of the scratches were not of sufficient magnitude to increase the wear of ultra-high-molecular-weight polyethylene above that of the negative controls.

A simulator study of adverse wear with metal and cement debris contamination in metal-on-metal hip bearings

Objectives

Third-body wear is believed to be one trigger for adverse results with metal-on-metal (MOM) bearings. Impingement and subluxation may release metal particles from MOM replacements. We therefore challenged MOM bearings with relevant debris types of cobalt–chrome alloy (CoCr), titanium alloy (Ti6Al4V) and polymethylmethacrylate bone cement (PMMA).

Methods

Cement flakes (PMMA), CoCr and Ti6Al4V particles (size range 5 µm to 400 µm) were run in a MOM wear simulation. Debris allotments (5 mg) were inserted at ten intervals during the five million cycle (5 Mc) test.

Results

In a clean test phase (0 Mc to 0.8 Mc), lubricants retained their yellow colour. Addition of metal particles at 0.8 Mc turned lubricants black within the first hour of the test and remained so for the duration, while PMMA particles did not change the colour of the lubricant. Rates of wear with PMMA, CoCr and Ti6Al4V debris averaged 0.3 mm³/Mc, 4.1 mm³/Mc and 6.4 mm³/Mc, respectively.

Conclusions

Metal particles turned simulator lubricants black with rates of wear of MOM bearings an order of magnitude higher than with control PMMA particles. This appeared to model the findings of black, periarticular joint tissues and high CoCr wear in failed MOM replacements. The amount of wear debris produced during a 500 000-cycle interval of gait was 30 to 50 times greater than the weight of triggering particle allotment, indicating that MOM bearings were extremely sensitive to third-body wear.

Cite this article: Bone Joint Res 2015;4:29–37.

Interactions between mammalian cells and nano- or micro-sized wear particles: physico-chemical views against biological approaches

Total joint arthroplasty (TJA) is a more and more frequent approach for the treatment of end-stage osteoarthritis in young and active adults; it successfully relieves joint pain and improves function significantly enhancing the health-related quality of life. Aseptic loosening and other wear-related complications are some of the most recurrent reasons for revision of TJA. This review focuses on current understanding of the biological reactions to prosthetic wear debris comparing in vivo and in vitro results. Mechanisms of interactions of various types of cells with metal, polymeric and ceramic wear particles are summarised. Alternative views based on multidisciplinary approaches are proposed to consider physico-chemical, surface parameters of wear particles (such as: particle size, geometry and charge) and material (particle chemical composition and its nature) with biological effects (cellular responses).

Profiling the third-body wear damage produced in CoCr surfaces by bone cement, CoCr, and Ti6Al4V debris: A 10-cycle metal-on-metal simulator test

Particles of bone cement (polymethyl methacrylate), CoCr and Ti6Al4V were compared for their abrasion potential against CoCr substrates. This appears to be the first study utilizing CoCr and Ti6Al4V particulates to abrade CoCr bearings and the first study profiling the morphology of third-body abrasive wear scratches in a hip simulator. The 5 mg debris allotments (median size range 140–300 µm) were added to cups mounted both inverted and anatomically with metal-on-metal (MOM) bearings in a 10-cycle, hip simulator test. Surface abrasion was characterized by roughness indices and scratch profiles. Compared to third-body abrasion with metal debris, polymethyl methacrylate debris had minimal effect on the CoCr surfaces. In all, 10 cycles of abrasion with metal debris demonstrated that roughness indices (Ra, PV) increased approximately 20-fold from the unworn condition. The scratch profiles ranged 20–108 µm wide and 0.5–2.8 µm deep. The scratch aspect ratio (W/PV) averaged 0.03, and this very low ratio indicated that the 140 µm CoCr beads had plastically deformed to create wide but shallow scratches. There was no evidence of transfer of CoCr beads to CoCr bearings. The Ti64 particles produced similar scratch morphology with the same aspect ratio as the CoCr particulates. However, the titanium particulates also showed a unique ability to flatten and adhere to the CoCr, forming smears and islands of contaminating metal on the CoCr bearings. The morphology of scratches and metal transfer produced by these large metal particulates in the simulator appeared identical to those reported on retrieved metal-on-metal bearings.

Articulating spacers used in two-stage revision of infected hip and knee prostheses abrade with time

BACKGROUND

Articulating spacers used in two-stage revision surgery of infected prostheses have the potential to abrade and subsequently induce third-body wear of the new prosthesis.

QUESTIONS/PURPOSES

We asked whether particulate material abraded from spacers could be detected in the synovial membrane 6 weeks after implantation when the spacers were removed for the second stage of the revision.

PATIENTS AND METHODS

Sixteen hip spacers (cemented prosthesis stem articulating with a cement cup) and four knee spacers (customized mobile cement spacers) were explanted 6 weeks after implantation and the synovial membranes were removed at the same time. The membranes were examined by xray fluorescence spectroscopy, xray diffraction for the presence of abraded particles originating from the spacer material, and analyzed in a semiquantitative manner by inductively coupled plasma mass spectrometry. Histologic analyses also were performed.

RESULTS

We found zirconium dioxide in substantial amounts in all samples, and in the specimens of the hip synovial lining, we detected particles that originated from the metal heads of the spacers. Histologically, zirconium oxide particles were seen in the synovial membrane of every spacer and bone cement particles in one knee and two hip spacers.

CONCLUSIONS

The observations suggest cement spacers do abrade within 6 weeks. Given the presence of abrasion debris, we recommend total synovectomy and extensive lavage during the second-stage reimplantation surgery to minimize the number of abraded particles and any retained bacteria.

[Preclinical evaluation of coated knee implants for allergic patients]

BACKGROUND

10-15% of the population show allergic reactions against skin contact to metals as nickel, cobalt or chromium and have thus a risk of not tolerating implants containing those materials. The relationship between periimplantary hypersensivity reaction and given cutaneous contact allergy is currently unknown. A new developed multilayer coating system is supposed to prevent long-term allergic reactions that may result from uncoated implants.

METHODS

Stability and function (concerning bonding durability, wear and ion release to the serum) of the multilayer coating system has been examined in a test series.

RESULTS

The specific architecture of the multilayer coating system evidences a very good bonding durability. The results of the test in the simulator show a reduction of wear of approximately 60% compared to the uncoated implants. Ion concentrations within the serum of the wear tests were by magnitudes lower than those measured in reference tests on uncoated components.

CONCLUSION

The results of the preclinical evaluation prove that the durability and function of the multilayer coating system are as intended.

The effect of entrapped bone particles on the surface morphology and wear of polyethylene

Clinically retrieved highly cross-linked ultrahigh molecular weight polyethylene (HXPE) acetabular liners have demonstrated scratching, whereas conventional ultrahigh-molecular-weight polyethylene (UHMWPE) implants show a smoother surface early after implantation. In the present study, the potential of bone particles and soft tissues, rather than cement, to scratch the articular surface of HXPE and UHMWPE (gamma radiated) acetabular components was evaluated; multiple bone particles located at the articular surface for 3600 simulated walking cycles replicated the scratches observed on retrieved implants. By remelting, these scratches were confirmed to be due to plastic deformation of the polyethylene, not wear. Furthermore, it was shown using wear testing that these scratches did not affect the subsequent wear rate of HXPE or conventional UHMWPE. Wear rates of scratched conventional and cross-linked polyethylene were not significantly different from unscratched conventional and cross-linked polyethylene, respectively.

[Should monobloc cemented stems be systematically revised during revision total hip arthroplasty? A prospective evaluation]

PURPOSE OF THE STUDY

The main reason for revision of Charnley type total hip arthroplasty is socket loosening related to high polyethylene wear and periacetabular osteolysis. In these situations, the monobloc cemented stem is frequently not loosened and it is not clear whether the femoral component can be retained during the revision procedure. The aim of this study was to evaluate surface and sphericity damage to the femoral head of a prospective and consecutive series of revision total hip arthroplasties during which the cemented monobloc femoral component has been systematically revised.

MATERIALS AND METHODS

We performed 22 revisions of both components of Charnley type cemented total hip arthroplasties. In all cases, the 22.2 mm head of the monobloc femoral component was made of 316 L stainless steel. The international standard for such femoral heads includes an average surface roughness (Ra) of 0.05 microm, a total roughness (Rt) value of 0.5 microm and a sphericity of +/-5 microm. The mean age of the patients at the time of the index arthroplasty was 51.3 years. The average time to revision was 14.8 years (seven to 25 years). The reasons for revision included isolated socket loosening (12), extensive periacetabular osteolysis without socket loosening (two), recurrent dislocation associated with socket loosening (one), sepsis without implant loosening (one), loosening of both components (one), and isolated loosening of the femoral component (five). Hence, 15 of the 22 (68.2%) femoral components could theoretically have been retained. The surface roughness of the femoral heads was evaluated using a contact-type profilometer. For each head, the apex and two zones, either macroscopically scratched or with loss of the mirror finish, were analyzed. Moreover, the sphericity of the heads was measured using a spherometer.

RESULTS

The stem explanted after recurrent dislocation was analyzed separately as the femoral head had major scratches. The mean Ra and Rt of the series at the apex was 0.029 and 0.876 microm, respectively. The mean Ra and Rt of the series for the macroscopically damaged areas was 0.05 microm and 1.540 microm, respectively. The mean sphericity of the series was 7.2 microm. Hence among the 22 explanted stems, 10 femoral heads (45.4%) had Ra or Rt apex and 18 (81.8%) Ra or Rt scratched area values beyond ISO standards, respectively. Sphericity was greater than +/-5mm for 13 of the 22 femoral heads (59.1%). With the numbers available, the age at the time of the index arthroplasty, the BMI, the time and the reason for revision were not significantly associated with the degree of femoral head damage for both roughness and sphericity parameters.

DISCUSSION

Retaining the femoral component during revision of the total hip arthroplasty including a monobloc femoral component is theoretically an interesting alternative. However, femoral head surface damage occurring in vivo would have lead us to retain severely scratched heads in over 80% of the hips, and heads with abnormal roughness and sphericity values in over 90% of the hips. Bases upon our results, we recommend systematically revising the femoral component during revision THA including a monobloc stem, irrespective of the reason for revision.

New radiopaque acrylic bone cement. II. Acrylic bone cement with bromine-containing monomer

Bromine-containing methacrylate, 2-(2-bromopropionyloxy) ethyl methacrylate (BPEM), had been used in the formulation of acrylic radiopaque cements. The effect of this monomer incorporated into the liquid phase of acrylic bone cement, on the curing parameters, thermal properties, water absorption, density, compression tests and radiopacity was studied. A decrease of maximum temperature and an increase of the setting time were observed with the addition of the bromine-containing monomer in the radiolucent cement composition. Adding BPEM in radiolucent acrylic bone cements composition results in the decrease of glass transition temperature and increase of its thermal stability. Acrylic bone cements modified with bromine-containing comonomer are characterized by polymerization shrinkage lower than the radiolucent cement. Addition of bromine-containing comonomer in radiolucent acrylic bone cement composition determines the increase of compressive strength. Acrylic bone cements modified with bromine-containing comonomer proved to be radiopaque.

Effect of iodixanol particle size on the mechanical properties of a PMMA based bone cement

Iodixanol (IDX) is a water soluble opacifier widely used in radiographical examinations of blood vessels and neural tissue, and it has been suggested as a potential contrast media in acrylic bone cement. The effect of the iodixanol particle size on the polymerisation process of the bone cement, the molecular weight, and the quasi-static mechanical properties have been investigated in this article. The investigation was performed using radiolucent Palacos powder mixed with 8 wt% of iodixanol with particle sizes ranging from 3 to 20 microm MMD, compared with commercial Palacos R (15 wt% ZrO2) as control. Tensile, compressive and flexural tests showed that smaller particles (groups with 3, 4, and 5 microm particles) resulted in significantly lower mechanical properties than the larger particles (groups with 15, 16, and 20 microm particles). There was no difference in molecular weight between the groups. The thermographical investigation showed that the IDX cements exhibit substantially lower maximum temperatures than Palacos R, with the 4 microm IDX group having the lowest maximum temperature. The isothermal and the constant rate differential scanning calorimetry (DSC) did not show any difference in polymerisation heat (DeltaH) or glass transition temperature (Tg) between radiolucent cement, or cement containing either IDX, or ZrO2. The findings show that the particle size for a bone cement containing iodixanol should be above 8 microm MMD.

In vitro and in vivo biological responses to a novel radiopacifying agent for bone cement

Iodixanol (IDX) and iohexol (IHX) have been investigated as possible radiopacification agents for polymethylmethacrylate (PMMA) bone cement, to replace the currently used barium sulphate and zirconia. IDX and IHX are both water-soluble iodine-based contrast media and for the last 20 years have been used extensively in clinical diagnostic procedures such as contrast media enhanced computed tomography, angiography and urography. One of the major reasons to remove the current radiopacifying agents is their well-documented cytotoxicity and their potential to increase bone resorption. Using in vitro bone resorption assays, the effect of PMMA particles plus IDX or IHX to induce osteoclast formation and lacunar resorption on dentine slices has been investigated. These responses have been compared with the in vitro response to PMMA particles containing the conventional radiopacifying agents, that is, barium sulphate and zirconia. In parallel, the in vivo reaction, in terms of new bone formation, to particles of these materials has been tested using a bone harvest chamber in rabbit tibiae. In vitro cell culture showed that PMMA containing IHX resulted in significantly less bone resorption than PMMA containing the conventional opacifiers. In vivo testing, however, showed no significant differences between the amounts of new bone formed around cement samples containing the two iodine-based opacifying agents in particulate form, although both led to fewer inflammatory cells than particles of PMMA containing zirconia. Our results suggest that a non-ionic radiopacifier could be considered as an alternative to the conventional radiopacifying agents used in biomaterials in orthopaedic surgery.

Prediction of scratch resistance of cobalt chromium alloy bearing surface, articulating against ultra-high molecular weight polyethylene, due to third-body wear particles

The entrapment of abrasive particles within the articulation between a cobalt chromium alloy (CoCrMo) femoral component and an ultra-high molecular weight polyethylene (UHMWPE) cup of artificial hip joints or tibial inserts of artificial knee joints usually scratches the metallic bearing surface and consequently increases the surface roughness. This has been recognized as one of the main causes of excessive polyethylene wear, leading to osteolysis and loosening of the prosthetic components. The purpose of this study was to use the finite element method to investigate the resistance of the cobalt chromium alloy bearing surface to plastic deformation, as a first approximation to causing scratches, due to various entrapped debris such as bone, CoCrMo and ZrO2 (contained in radiopaque polymethyl methacrylate cement). A simple axisymmetric micro contact mechanics model was developed, where a spherical third-body wear particle was indented between the two bearing surfaces, modelled as two solid cylinders of a given diameter, under the contact pressure determined from macro-models representing either hip or knee implants. The deformation of both the wear particle and the bearing surfaces was modelled and was treated as elastic-plastic. The indented peak-to-valley height on the CoCrMo bearing surface from the finite element model was found to be in good agreement with that reported in a previous study when the third-body wear particle was assumed to be rigid. Under the physiological contact pressure experienced in both hip and knee implants, ZrO2 wear particles were found to be fully embedded within the UHMWPE bearing surface, and the maximum von Mises stresses within the CoCrMo bearing surface reached the corresponding yield strength. Consequently, the CoCrMo bearing surface was deformed plastically and the corresponding peak-to-valley height (surface roughness) was found to increase with both the hardness and the size of the wear particle. Even in the case of CoCrMo wear particles, with similar mechanical properties to those of the CoCrMo bearing surface, a significant plastic deformation of the bearing surface was also noted; this highlighted the importance of considering the deformation of the wear particles. These findings support the hypotheses made by clinical studies on the contribution of entrapped debris to increased surface roughness of CoCrMo femoral bearing surfaces.

A novel test method for evaluation of the abrasive wear behaviour of total hip stems at the interface between implant surface and bone cement

After total hip replacement, some cemented titanium stems show above-average early loosening rates. Increased release of wear particles and resulting reaction of the peri-prosthetic tissue were considered responsible. The objective was to develop a test method for analysing the abrasive wear behaviour of cemented stems and for generating wear particles at the interface with the bone cement.

By means of the novel test device, cemented hip stems with different designs, surface topographies and material compositions using various bone cements could be investigated. Before testing, the cemented stems were disconnected from the cement mantle to simulate the situation of stem loosening (debonding). Subsequently, constant radial contact pressures were applied on to the stem surface by a force-controlled hydraulic cylinder. Oscillating micromotions of the stem (± 250 μm; 3 × 106cycles; 5 Hz) were carried out at the cement interface initiating the wear process.

The usability of the method was demonstrated by testing geometrically identical Ti-6A1-7Nb and Co-28Cr-6Mo hip stems ( n = 12) with definite rough and smooth surfaces, combined with commercially available bone cement containing zirconium oxide particles. Under identical frictional conditions with the rough shot-blasted stems, clearly more wear particles were generated than with the smooth stems, whereas the material composition of the hip stems had less impact on the wear behaviour.

Third-body wear testing of a highly cross-linked acetabular liner: the effect of large femoral head size in the presence of particulate poly(methyl-methacrylate) debris

The hip simulator wear performance of an electron beam cross-linked and subsequently melted ultrahigh molecular weight polyethylene against femoral heads of 28-, 38-, and 46-mm diameter in the presence of poly(methyl-methacrylate) particulate debris was contrasted with that of conventional polyethylene against a 46-mm diameter head. Over 5 million cycles of testing, the average wear rate of the conventional polyethylene liners was 29.3 +/- 3.0 mg per million cycles. All highly cross-linked components exhibited marked reduction in wear, with the highest wear measuring 0.74 +/- 0.85 mg per million cycles. This study, using a clinically relevant third-body material, showed the electron beam cross-linked material to be far more resistant to this third-body wear than conventional ultrahigh molecular weight polyethylene, even when very large diameter femoral heads were used.

Bone cement X-ray contrast media: A clinically relevant method of measuring their efficacy

It is important to compare different contrast media used in bone cement according to their ability to attenuate X-rays and thereby produce image contrast between bone cement and its surroundings in clinical applications. The radiopacity of bone cement is often evaluated by making radiographs of cement in air at an X-ray tube voltage of 40 kV. We have developed a method for ranking contrast media in bone cement simulating the clinical situation, by (1) choosing the same X-ray tube voltage as used in clinical work, and (2) using a water phantom to imitate the effects of the patients' soft tissue on the X-ray photons. In clinical work it is desirable to have low radiation dose, but high image contrast. The voltage chosen is a compromise, because both dose and image contrast decrease with higher voltage. Three contrast media (ZrO(2), BaSO(4), and Iodixanol) have been compared for degree of "image contrast." Comparing 10 wt % contrast media samples at an X-ray tube voltage of 40 kV, ZrO(2) produced higher image contrast than the other media. However, at 80 kV, using a water phantom, the results were reversed, ZrO(2) produced lower image contrast than both BaSO(4) and Iodixanol. We conclude that evaluations of contrast media should be made with voltages and phantoms imitating the clinical application.

Water uptake and release from iodine-containing bone cement

Water uptake and release characteristics of PMMA cement containing the water-soluble contrast media iohexol or iodixanol have been investigated. The water uptake study revealed that iohexol had the highest uptake of water (3.7%) and that iodixanol had an uptake close to that of Palacos R (2.3% and 1.9%). The curves obtained showed the materials to follow classic diffusion theory, with an initial linearity with respect to t(1/2) making it possible to calculate the diffusion coefficients. This showed iohexol to have the lowest diffusion coefficient, Palacos R the highest, and iodixanol close to that of Palacos R. The release study showed that more iohexol than iodixanol was released from the bone cement; the long-term release was above 25 microg/mL for iohexol compared to slightly above 10 microg/mL for iodixanol. A microCT investigation showed that the risk of developing an observable radiolucent zone is negligible.

Third-body wear of highly cross-linked polyethylene in a hip simulator

The wear performance of a radiation cross-linked melted ultrahigh-molecular-weight polyethylene (UHMWPE) articulating against 28-mm cobalt chrome femoral heads in the presence of third-body particulate debris was investigated in a hip simulator and compared with the wear of conventional UHMWPE. Particles of aluminum oxide or bone cement containing barium sulfate were added to the serum. In the presence of aluminum oxide particles, the incremental wear rates of conventional UHMWPE averaged as high as 149 +/- 116 mg/million cycles compared with 37 +/- 38 mg/million cycles for the highly cross-linked components. The difference in the average weight loss was statistically significant at P <.01. With bone cement particles, the conventional UHMWPE components had an average incremental wear rate of 19 +/- 5mg/million cycles, and the wear rate of the highly cross-linked UHMWPE components was 0.5 +/- 0.7 mg/million cycles.

Long-term survival of Stanmore total hip replacements inserted with radiolucent bone cement

Radio-opacifiers in bone cements are an accepted part of every-day practice. They have, however, been shown to be a potential cause of an increase in third body wear and to excite bone resorption in in vitro and in vivo studies. We reviewed the results of 228 consecutive Stanmore total hip replacements performed between 1981 and 1985 in 211 patients. All were inserted with radiolucent bone cement. Information regarding whether the prosthesis had been revised was available for all patients. Seventy-three patients (83 hips) were still alive and 41 patients (44 hips) were sufficiently healthy to attend clinic. Information regarding pain level was obtained from the remaining 32 patients. When revision of the implant was taken as the end-point, there was 95% ten-year survival, 91% fifteen-year survival and 75% eighteen-year survival. These long-term results of Stanmore THRs, performed in a district general hospital, with radiolucent bone cement, compare favourably with the other published series for this implant. We did not find the inability to see the bone cement a particular disadvantage when reviewing radiographs for signs of loosening. (Hip International 2002; 12: 274-80).

Mechanical performance of acrylic bone cements containing different radiopacifying agents

The effect that three different radiopacifying agents, two of them inorganic (BaSO4, ZrO2) and one organic (an iodine containing monomer, IHQM) have on the static and dynamic mechanical properties of acrylic bone cements was studied. Compressive and tensile strength, fracture toughness and fatigue crack propagation were evaluated. The effect of the inorganic fillers depends on their size and morphology. In relation to the radiolucent cement, the addition of zirconium dioxide improved significantly the tensile strength, the fracture toughness and the fatigue crack propagation resistance. In contrast, the addition of barium sulphate produced a decrease of the tensile strength, but did not affect the fracture toughness and improved the crack propagation resistance. When the iodine containing monomer was used, although the tensile strength and the fracture toughness increased, the fatigue crack propagation resistance remained as low as it was for the radiolucent cement.

Contamination of polyethylene cups with polymethyl methacrylate particles: an experimental study

The articulating surfaces of 6 ultra-high molecular weight polyethylene cups were exposed to curing polymethyl methacrylate (PMMA) bone-cement and examined with scanning electron microscopy and laser ablation inductively coupled plasma mass spectrometry (LA-ICPMS). Three of the cups were exposed to blood and bone-cement, and the rest were exposed to bone-cement only. After removal of the bone-cement bulk, PMMA particles were found and identified in all 6 cups. The particles were verified by identifying zirconium with energy-dispersive x-ray fluorescence spectroscopy in 5 cups and with LA-ICPMS in 1 cup. The degree of surface contamination was estimated with LA-ICPMS. The number of zirconium-containing particles detected was on average 10 to 20/mm2. PMMA bone-cement left in polyethylene cups during polymerization can contaminate the articulating surface with adherent PMMA particles.

Wear of ultra-high molecular weight polyethylene (UHMWPE) in total knee prostheses: a review of key influences

The formation and development of wear is now widely accepted as one of the major concerns in the long-term survivorship of contemporary knee prostheses in vivo. This review examines the role of surface topography, third-body debris, load, contact mechanics and material quality in the wear process. Some of the kinematic and physiological issues that need to be modelled in the development of wear testing regimes for evaluation of material combinations and geometrical combinations in total knee implant designs are considered. Wear testing procedures and some of the results from wear tests are discussed and the need to consider the impact of rolling and sliding in the study of wear in total knee components is highlighted. The dominant wear mechanisms that occur in vivo are identified and the role of these mechanisms is currently being examined experimentally at the University of Limerick wear testing machine.

Surface roughness of retrieved CoCrMo alloy femoral components from PCA artificial total knee joints

In this study, we analyzed the surface roughness of retrieved cobalt-chromium-molybdenum (CoCrMo) femoral components of porous coated anatomic (PCA) artificial total knee joints, using a white light interference surface profilometer (WLISP). Thirty-eight PCA retrieved specimens obtained from the Anderson Clinic (Arlington, VA) were used. The artificial knees were originally implanted between 1982-1993, and the specimens were retrieved during revision surgeries between 1988-1996. We examined specimens damaged by three wear modes: femoral component against the ultra high molecular weight polyethylene (UHMWPE) articular surface (mode I), femoral component against the metal tibial tray (because of UHMWPE tibial component wear-through) (mode II), and femoral component against metal-debris-embedded-UHMWPE (with metal debris from the porous coating) (mode III). The mean surface roughness of each femoral component was the average of 80 surface roughness measurements. The in vivo alloy femoral component surfaces were rougher by an order of magnitude over controls, and the alloy surfaces were predominantly worn by the formation of parallel scratches in the direction of articulation. There was no correlation between the surface roughness of the femoral components and patient age, sex, weight, and total time of implantation. Significant surface roughness increases accompanied mode II and mode III wear. Different carbide morphologies were found on different femoral component surfaces, indicating that a variety of sintering processes, with different times and temperatures, may have been applied to the alloy femoral components during manufacture. Metal component roughness may be important to the wear of UHMWPE components and the success of total artificial knee joint.

Surface roughness quantification of CoCrMo implant alloys

The articulating surfaces of CoCrMo alloy wear specimens and retrieved femoral components of artificial total knee joints are subject to uneven wear. A repeatable and reliable measurement method is necessary to evaluate the surface damage. In this study, the surface roughness of CoCrMo alloy specimens subjected to in vitro third-body wear, and retrieved femoral components of knee joints were analyzed using a white light interference surface profilometer. Each third-body wear specimen was divided into a 19x19 grid of 1-mm(2) squares (361 squares) and each femoral condyle of retrieved specimens was divided into two 10x10 grids of 1-mm(2) squares (100 squares). The surface roughness average (Ra) and root mean square roughness (RMS) were measured for each of the squares. The average of all points measured was defined as the true surface roughness mean (TSRM). Measurements were then performed on 40-60 (in vitro specimens) or 30 (retrieved specimens) randomly selected points on each surface and a cumulative average was calculated. The cumulative average surface roughness value from only a few (5-15) measurement points generated large deviations (>40%) from the TSRM, but converged to the TSRM as the number of measurements increased. The number of randomly selected points necessary for the cumulative average roughness to be within 10% of the TSRM was defined as the representative measurement number (RMN). The RMN for the third-body wear specimens (surface area of 573 mm(2)) was 40 points, and the RMN for the retrieved femoral components (surface area of 100 mm(2)) was 20 points. To obtain the cumulative surface roughness average within a desired percentage of the TSRM, it is important to define or experimentally determine the critical minimum number of measurements, RMN. Several types of measurements may be necessary to understand wear and damage on metal components of artificial knee joints. The TSRM represents a consistent and reproducible measure of surface damage, and a starting point to develop appropriate measurement protocols to quantify damage on a specific surface.

Prediction of plastic strains in ultra-high molecular weight polyethylene due to microscopic asperity interactions during sliding wear

Studies of explanted femoral heads have shown that scratches caused by bone cement, bone or metallic particles are present on the rubbing surface. This damage has been cited as a cause of increased wear of ultra-high molecular weight polyethylene (UHMWPE) acetabular cups and it is known that the particulate wear debris produced leads to osteolysis. A series of explanted Charnley femoral heads have been surface characterized using a Talysurf 6 profilometer and found to have scratches with lip heights in the size range 0.1-3.25 microns with an average height of 1 micron giving an average aspect ratio (defined as height/half-width) of 0.1. These geometries were incorporated into a finite element model of a stainless steel asperity sliding over UHMWPE under conditions similar to those in an artificial hip system. It was found that as the aspect ratio of the asperity lip increased, the plastic strains both on and below the surface of the UHMWPE increased non-linearly, but that the magnitude of the strain was independent of the asperity height. The asperity aspect ratio was also found to affect the position of the maximum sub-surface strain, as the asperity aspect ratio was increased the maximum strain rose to the surface. The high plastic strains predicted offer an explanation for the highly elevated wear rates in scratched counterface tests and the aspect ratio of scratch lips is therefore a critical determinant of plastic strain.

The effect of surface topography of retrieved femoral heads on the wear of UHMWPE sockets

The study was undertaken to investigate the association, if any, between the surface roughness of 35 explanted femoral heads and the clinical wear factors of the corresponding polyethylene sockets. The wear of the socket was measured using a shadowgraph technique. The surface topography was investigated using a Rodenstock RM 600 non-contacting profilometer, and six parameters were used to characterise the roughness. Further, qualitative inspections of the femoral surface were undertaken using both a Joel JSM-IC-848 scanning electron microscope and a Zeiss Axiotech microscope with a differential interference contrast facility. Two parameters were found to correlate with the clinical wear factor, namely the skewness of the amplitude distribution function, Sk, and the arithmetic mean roughness, Ra. Simple parameters describing the peak heights of the asperities were found not to have a significant association with the clinical wear factor. The exponent in the power relationship between the arithmetic mean roughness and kclinical was found to be equal to 0.5 (SE: 0.2). This value is significantly smaller than that found in laboratory experiments and may be due to the non-uniform nature of the roughening of the femoral head, three-body wear and the effect of other clinical factors on the wear process. Further, extremely strong correlations were detected between the differing roughness parameters, which would suggest that any attempt to deduce which one is the most important in affecting the wear of the polymeric counterface is fraught with difficulty. However, further investigation of those parameters, such as the reduced peak height or the material filled profile peak area, which may better describe the effect of the counterface on the wear of the UHMWPE surface would appear to be prudent.

The wear of ultra-high molecular weight polyethylene sliding on metallic and ceramic counterfaces representative of current femoral surfaces in joint replacement

A number of studies have investigated the influence of surface roughness on the wear of ultra-high molecular weight polyethylene (UHMWPE) in total joint replacement. The results of these studies have shown that the wear factor is proportional to the counterface roughness raised to a power greater than one. In this laboratory study, the effect of surface finish of several biomaterials on the wear of UHMWPE was studied. The study was conducted using reciprocating pin-on-plate wear tests with bovine serum as a lubricant. The biomaterials investigated as the counterface material included stainless steel, cast cobalt chrome (CoCr), CoCr (ASTM F799), alumina ceramic and zirconia ceramic. The counterface topographies of the wear plates were produced using techniques representative of current manufacturing methods. The surface roughness of the wear plates was varied in the range Ra = 0.005-0.04 micron; this was representative of femoral heads and femoral knee components currently used clinically. Metals and ceramics with a similar surface roughness produced a similar wear rate of UHMWPE. For the limited range of smooth counterfaces used in this study only a moderate correlation was found between the surface roughness and the wear factors. For a change in counterface roughness Ra of 0.005 to 0.04 micron, the wear factor increased from 7.4 +/- 1.6 to 16.5 +/- 2.4 x 10(-9) mm3/N m (mean +/- standard error). This variation in counterface roughness had much less effect in wear than previously reported for rougher counterfaces. For an extended range of counterface roughness, a stronger correlation was found using an exponential function for the regression fit. The exponential function shows the benefits of decreased wear with decreased surface roughness. Although the wear rate decreased less rapidly with decreased counterface roughness for Ra values below 0.05 micron, there were significant advantages to be gained from improved femoral head roughness to below 0.01 micron Ra.

Wear of ultra-high molecular weight polyethylene acetabular cups in a physiological hip joint simulator in the anatomical position using bovine serum as a lubricant

The Leeds physiological anatomical (PA) hip joint simulator was developed to apply three axes of loading and a complex three-dimensional motion so that the forces and motions can reproduce exactly the walking cycles defined by Paul. This paper presents the results of a study using the Leeds PA hip joint simulator to determine the wear of 32 mm ultra-high molecular weight polyethylene (UHMWPE) acetabular cups against stainless steel and zirconia ceramic heads, using bovine serum as lubricant. These results have been compared with the results of a previous study that used water as the lubricant, which led to UHMWPE transfer film being formed on the stainless steel head. Comparisons are also made with clinical results and results from other simulators. The study indicates that it is preferable to use bovine serum in simulator studies. In addition, the results indicate that if the surface roughness of the metallic and femoral heads are similar, and they remain undamaged during the tests, the wear rates of the UHMWPE cups are likely to be similar.

Effect of counterface material on the characteristics of retrieved uncemented cobalt-chromium and titanium alloy total hip replacements

A number of total hip components explanted at revision with bearing surfaces in either cobalt-chromium-molybdenum alloy or titanium-6% aluminium-4% vanadium alloy were examined and compared to contemporaneously manufactured but unused items; particular attention was paid to the bearing surfaces which were examined visually, by low-power microscopy, scanning electron microscopy (SEM), confocal microscopy, white light interferometry, laser profilometry and conventional stylus profilometry. The cobalt alloy heads maintained their surface finish well over periods up to 12 years. The titanium implants became badly damaged over much shorter periods although even badly scratched heads continued to meet the current standards for titanium alloy heads. Analysis showed that the damage to the titanium alloy heads was not a random but a well-defined process of scarring of a consistent size created by abrasion with small particles of bone. These damaged heads had the potential to wear the matching UHMWPE components rapidly creating large amounts of polymer debris. The finding that measurement of these damaged heads is within current standards raises concerns as to whether current standards incorporate fully the requirements for clinical performance.

Wear testing of materials and surfaces for total knee replacement

A simple wear test was investigated for evaluating the wear and damage of material pairs when used in total knee replacement. The test consisted of an axially loaded metallic femoral indentor and a reciprocating ultrahigh molecular weight polyethylene (UHMWPE) flat disk that represented the tibial component. A number of variables were studied including the effect of conformity by varying the radii of the femoral surface, distilled water or serum as a lubricant, different femoral materials, and different types of UHMWPE. In general, the different morphologies of the surface wear of the UHMWPE were similar to those seen on retrieved total knee replacements. Increased conformity with a cylindrical indentor gave a reduced wear rate initially, compared with that of the lower conformity spherical indentor. However, the wear rates were similar subsequent to this initial wearing in phase. Transfer films of UHMWPE were observed on the cobalt-chrome indentors for both serum and distilled water lubrication, although this film was more extensive for distilled water. The lowest wear rate was observed when oxidized zirconium was used on the femoral side, which was attributed to greater wettability, surface hardness, and immunity to oxidative wear. Tests using cobalt-chrome femoral cylinders and different grades of UHMWPE showed different wear rates. Of these PEs, GUR 415 showed less wear than both RCH 1000 and UHMWPE containing numerous fusion defects. For the latter, wear was attributed to a fatigue mechanism, although in most cases it was associated with surface phenomena rather than subsurface cracking. However, in some specimens of UHMWPE subsurface crack propagations occurred with defects. The test method is discussed in relation to its applicability to the evaluation and comparison of bearing materials and surfaces, with particular application to total knee replacements.

Design of a non-constrained, non-cemented, modular, metacarpophalangeal prosthesis

A non-constrained, non-cemented, modular prosthesis for replacement of the metacarpophalangeal joints of the fingers has been developed. The prosthesis is of a surface design which is modular in construction and is implanted into the bones with a press fit. The prosthesis is designed to be implanted into patients with traumatic injuries, post-traumatic osteoarthritis and into patients with rheumatoid arthritis at an early stage in the disease where the muscles and ligaments that surround the joint are still functional and can provide joint stability.

Comparative study of the wear of UHMWPE with zirconia ceramic and stainless steel femoral heads in artificial hip joints

The wear of ultra high molecular weight polyethylene (UHMWPE) when sliding against zirconia ceramic and stainless steel counterfaces has been compared in a pin-on-plate reciprocator and in a hip joint simulator. A lower wear factor was found for the UHMWPE when sliding on the zirconia ceramic counterfaces in the pin-on-plate tests. In the hip joint simulator test, the acetabular cups articulating on zirconia heads showed consistently lower volume changes than the cups articulating on stainless steel heads. The higher volume changes found with the stainless steel heads were associated with an increased roughness of the femoral heads during the tests. This roughening was caused by the adherence of a rough polymer transfer film.

Metacarpophalangeal joint prostheses: a review of past and current designs

The anatomy and biomechanics of the metacarpophalangeal (MCP) joint are briefly described. Hinge, flexible and surface designs of past and current MCP prosthetic joints are reviewed, outlining their respective advantages and disadvantages. Although existing prostheses can restore cosmetic appearance and relieve pain, none can equal the stability and versatility of the natural joint. Delayed reconstructive surgery may be partly responsible for the mediocre results experienced, since the later the surgery the worse will be the condition of the muscles and ligaments surrounding the joint. These are the structures responsible for strength, movement and stability of the joint. From a mechanical viewpoint it may be desirable to operate at an earlier stage of the disease than is currently indicated, but this is a clinical decision. Some design aspects, namely fixation and wear, require a different approach when designing an MCP prosthesis from that adopted in the case of prosthetic hips and knees.

Histopathological and microanalytical study of zirconium dioxide and barium sulphate in bone cement

AIMS

To report the appearances of zirconium dioxide and barium sulphate in interface membranes, synovium, and other tissues around joint prostheses.

METHODS

Histological sections from 23 specimens were reviewed by light microscopy and polarisation. Scanning electron microscopy and x ray microanalysis were performed on routinely processed paraffin wax sections.

RESULTS

Polyethylene, metals, and polymethylmethacrylate cement debris were easily recognisable. Almost all the cement remnants contained either zirconium dioxide or barium sulphate, confirmed by microanalysis. The contrast media had characteristic light microscopic appearances. Zirconium was identified in macrophages away from cement remnants.

CONCLUSION

The presence of radiographic contrast media in tissues around prosthetic joints is common but not widely recognised.

Tribology of human and artificial joints

Studies of human joint lubrication mechanisms have led to the conclusion that under normal healthy conditions they are fluid film lubricated. The main features responsible for allowing this mechanism to operate are the dynamic nature of the loading and the compliance of the bearing surfaces (articular cartilage). In contrast, artificial joints, being made of much more rigid materials, have been demonstrated to be lubricated by a mixed regime, where some load is carried by the fluid film and some by solid to solid contact. Since some surface contact takes place then wear remains a problem and friction is much higher than in human joints. The use of compliant surface bearings for artificial joints has been explored and shown to be of great advantage, reproducing the effects of natural joints. However, elastomeric materials are known to degrade in aqueous solutions so this aspect has been examined to ensure a reasonable life in the human body. Joints of the lower limb--hip, knee, and ankle--have similar load and motion patterns and behave in a similar way in terms of lubrication. Joints of the hand are not in any way similar in their behaviour and so a typical upper limb joint, the finger, has been studied to see if improvements can be made to the design of replacement artificial joints. Novel suggestions like plastic on plastic joints have been shown to be an alternative which is worthy of further consideration.

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.