Effects of the sample preparation temperature on the nanostructure of compression moulded ultrahigh molecular weight polyethylene

In this study, the effects of the sample sectioning temperature on the surface nanostructure and mechanical response of compression moulded ultrahigh molecular weight polyethylene (UHMWPE) at a nanometer scale (nanomechanical properties) have been characterized. The primary focus of this work was to determine if the sample sectioning temperature significantly changed the nanostructure of UHMWPE, while the secondary focus was to characterize the effect on the mechanical response due to the changes in the sectioned surface nanostructure. The goals of this study were: (a) to investigate the potential possibility of creating surface artefacts by the sample preparation technique by sectioning at different temperatures relative to the published range of glass transition temperatures, Tg, for PE (-12, -80 and -25 degrees C); (b) to determine the possibility of molecular orientation induced by plastic deformation of the UHMWPE sample during the process of sample preparation; (c) to measure the relative difference in nanomechanical properties owing to evolution of different nanostructures as a function of sample sectioning temperature. Field emission scanning electron microscopy (FESEM), atomic force microscopy (AFM) and nanoindentation were used to demonstrate that the sectioning temperature caused a change in nanostructure of the compression moulded UHMWPE sectioned surface, explaining the change in mechanical response to indentation at a nanoscale. In this study, it was demonstrated that significant plastic deformation occurs when a shear stress is applied between the glass or diamond blade and the UHMWPE during sample preparation under ambient conditions at a temperature of 22 degrees C. These results also suggest that an optimum sample sectioning temperature should definitely be below the measured Tg of the polymer.     

Improved wear resistance of ultra-high molecular weight polyethylene by plasma immersion ion implantation

Surface modification of ultra-high molecular weight polyethylene (UHMWPE) has been explored using the novel non-line-of-slight plasma immersion ion implantation (PIII) with nitrogen. The modified surfaces were characterised by SEM and a Nano Test 600 testing machine. The tribological behaviour of PIII treated UHMWPE sliding against AISI 316L stainless steel counterfaces was evaluated using a pin-on-disc tribometer under water lubricated conditions. The experimental results show that PIII is a very promising surface engineering technique to improve such surface mechanical properties as surface hardness and elastic modulus of UHMWPE. As a result, the wear resistance of UHMWPE was significantly enhanced by a factor of three following PIII treatment, as compared with untreated material. It was found that the significantly improved wear resistance of PIII treated UHMWPE can be mainly attributed to ion bombardment induced cross-linking, and thus surface hardening.     

Elasto-plastic contact analysis of an ultra-high molecular weight polyethylene tibial component based on geometrical measurement from a retrieved knee prosthesis

The wear phenomenon of ultra-high molecular weight polyethylene (UHMWPE) in knee and hip prostheses is one of the major restriction factors on the longevity of these implants. Especially in retrieved knee prostheses with anatomical design, the predominant types of wear on UHMWPE tibial components are delamination and pitting. These fatigue wear patterns of UHMWPE are believed to result from repeated plastic deformation owing to high contact stresses. In this study, the elasto-plastic contact analysis of the UHWMPE tibial insert, based on geometrical measurement for retrieved knee prosthesis, was performed using the finite element method (FEM) to investigate the plastic deformation behaviour in the UHMWPE tibial component. The results suggest that the maximum plastic strain below the surface is closely related to subsurface crack initiation and delamination of the retrieved UHMWPE tibial component. The worn surface whose macroscopic geometrical congruity had been improved due to wear after joint replacement showed lower contact stress at macroscopic level.     

Demonstration of a New Technique Using Radioisotope Tracers to Measure the Backside Wear Rate on Tibial Inserts

Local backside wear measurements on ultra-high molecular weight polyethylene (UHMWPE) tibial inserts in LCS mobile bearing knee prostheses have been performed using a new radioisotope tracing technique. The radioisotope tracers ⁹⁷Ru and ^101mRh were synthesized via a fusion evaporation reaction and recoil-implanted into cylindrical plugs of UHMWPE. The labelled plugs were carefully fitted into tibial inserts at two relevant locations. With bovine serum acting as a lubricant, the tibial inserts were then worn in vitro for 500,000 and 780,000 cycles, respectively, in a pneumatic knee motion simulator. Results reflect the non-linear change of wear during the wear-in phase and its evolution to a long-term steady-state rate. This new technique shows potential for extracting localized wear rates across the backside of a tibial insert in order to develop a comprehensive backside wear model.     

Reduction of total knee replacement wear with vitamin E blended highly cross-linked ultra-high molecular weight polyethylene

Ultra-high molecular weight polyethylene (UHMWPE) is a common bearing component in total knee replacement (TKR) implants, and its susceptibility to wear continues to be the long-term limiting factor in the life of these implants. This study hypothesized that in TKR systems, a highly cross-linked (HXL) UHMWPE blended with vitamin E will result in reduced wear as compared to a direct compression-moulded (DCM) UHMWPE. A wear simulation study was conducted using an asymmetric lateral pivoting '3D Knee' design to compare the two inserts. The highly cross-linked UHMWPE was aged prior to the testing and force-controlled wear testing was carried out for 5 million cycles using a load-controlled ISO-14243 standard at a frequency of 1 Hz on both groups. Gravimetric measurements of DCM UHMWPE (4.4 +/- 3.0 mg/million cycles) and HXL UHMWPE with vitamin E (1.9 +/- 1.9 mg/million cycles) showed significant statistical differences (p < 0.01) between the wear rates. Wear modes and surface roughness for both groups revealed no significant dissimilarities.     

Relative movements between Kinemax Plus tibial inserts and the tibial base-plates

Tests were performed on six large Kinemax Plus knee bearings (snap-fit design) to evaluate the amount of movement between 10- and 15-mm-thick tibial inserts and the tibial base plates. The knee bearings were tested up to 1 x 10(6) cycles on the Durham six-station knee wear simulator which subjected the bearings to similar motion and loading profiles that would be experienced by the natural knee during walking. Although passive internal/external (I/E) rotation was allowed, no active I/E rotation was applied. The movement of the tibial inserts was measured with dial gauges (accuracy +/-0.01 mm) before and after the bearings were tested on the simulator, when unloaded, and throughout the tests while the bearings were being dynamically loaded in the simulator. Movement occurred between the tibial insert and the tibial base plate after initial assembly due to the snap-fit mechanism used to locate the tibial insert within the tibial base plate. However this decreased appreciably when the bearings were loaded in the simulator. The amount of movement did not change with time when the bearings were continuously loaded in the simulator. However, after each test the amount of movement of the tibial inserts, when unloaded, was only 65 per cent (anterior-posterior) and 46 per cent (medial-lateral) of the values before the test. This was thought to be due to creep of the ultra-high molecular weight polyethylene (UHMWPE) inserts. The movement between the tibial insert and tibial base plate in situ is likely to be much less than that observed by a surgeon at the time of assembly due to loading of the knee bearing in the body. However, the amount of movement when the tibial inserts are loaded may still be great enough to produce a second interface where wear of the tibial insert may take place.     

Nanomechanical characterization of human hair using nanoindentation and SEM

Human hair is a nanocomposite biological fiber with well-characterized microstructures. Nanomechanical characterization of human hair can help to evaluate the effect of cosmetic products on hair surface, can provide a better understanding of the physicochemical properties of a wide variety of composite biological systems, and can provide the dermatologists with some useful markers for the diagnosis of hair disorders. The paper presents systematic studies of nanomechanical properties of human hair including hardness, elastic modulus and creep, using the nanoindentation technique. The samples include Caucasian, Asian and African hair at virgin, chemo-mechanically damaged and treated conditions. Hair morphology was studied using scanning electron microscopy (SEM). Indentation experiments were performed on both the surface and cross-section of the hair, and the indents were studied using SEM. The nanomechanical properties of hair as a function of hair composition, microstructure, ethnicity, damage and treatment are discussed.     

Temperature prediction in a finite element model for sliding contact analysis of total hip prosthesis

A finite-element model for sliding contact in total hip joint prosthesis is presented in this paper. The hip prosthesis studied consists of an ultra-high molecular weight polyethylene (UHMWPE) acetabular cup articulating against cobalt-chrome and alumina-ceramic femoral heads. Various aspects of prosthesis operation were analysed using the finite-element model. For example, bulk material and surface stresses were analysed under varying conditions of elastic modulus, friction coefficient, sliding speed, and radial clearance. The resulting variations of temperature were also recorded. The results obtained from the model are useful in understanding the operating conditions and the causes of wear in the hip prosthesis.     

Effect of ultra-high molecular weight polyethylene thickness on contact mechanics in total knee replacement

One of the important design parameters in current knee joint replacements is the thickness of the ultra-high molecular weight polyethylene (UHMWPE) tibial insert, yet there is no clear definition of the upper limit of the 'thick' polyethylene insert. Using one design knee implant and subjecting it to the physiological loads encountered throughout the gait cycle, measurements of the lengths of contact imprints generated were compared with the corresponding theoretical predictions for different insert thicknesses under the same applied load. Multiple regression analysis was applied to test whether the dimensions of contact imprints are influenced by UHMWPE thickness. Good agreement was obtained between the theoretical predictions and the experimental measurements of the dimensions of contact imprints when the knee was at 60 degrees flexion. Therefore, it was possible to estimate the contact pressure at the articulating surface using the theoretical model. Contact imprint dimensions increased with increasing applied load. Statistical analysis of the experimental data revealed that, at 0 degree flexion, the overall imprint dimensions increased as the UHMWPE thickness increased from 8 to 20 mm. However, the increment was not significant when the thickness subinterval 10-15 mm was considered. Furthermore, at 60 degrees flexion, thickness was not a significant factor for the overall imprint dimensions. No evidence was found from the data to suggest that an increment in polyethylene thickness over 10 mm would significantly reduce the contact imprint dimensions. These findings suggest that thicker inserts can be avoided, as they require unnecessary bone resection.     

A comparative study on performance of multilayer coated and uncoated carbide inserts when turning AISI D2 steel under dry environment

The present work deals with a comparative study on flank wear, surface roughness, tool life, volume of chip removal and economical feasibility in turning high carbon high chromium AISI D2 steel with multilayer MTCVD coated [TiN/TiCN/Al₂O₃/TiN] and uncoated carbide inserts under dry cutting environment. Higher micro hardness of TiN coated carbide samples (1880 HV) compared to uncoated carbide (1430 HV) is observed and depicts better resistance against abrasion. The low erosion rate was observed in TiN coated insert compared to uncoated carbide. The tool life of TiN coated insert is found to be approximately 30 times higher than the uncoated carbide insert under similar cutting conditions and produced lower surface roughness compared to uncoated carbide insert. The dominant wear mechanism was found to be abrasion and progression of wear was steady using multilayer TiN coated carbide insert. The developed regression model shows high determination coefficient i.e. R² = 0.977 for flank wear and 0.94 for surface roughness and accurately explains the relationship between the responses and the independent variable. The machining cost per part for uncoated carbide insert is found to be 10.5 times higher than the multilayer TiN coated carbide inserts. This indicates 90.5% cost savings using multilayer TiN coated inserts by the adoption of a cutting speed of 200 m/min coupled with a tool feed rate of 0.21 mm/rev and depth of cut of 0.4 mm. Thus, TiN coated carbide tools are capable of reducing machining costs and performs better than uncoated carbide inserts in machining D2 steel.     

Conductive composite of UHMWPE and CB as a dynamic contact analysis sensor

There has long been a need to experimentally measure the dynamic contact conditions of important engineering tribological systems, especially those with polymeric bearing surfaces that prove difficult to model. In order to experimentally quantify the dynamic contact conditions of geometrically complex polymeric bearing surfaces, a composite sensor material has been developed. In this study, qualitative morphological analysis of virgin ultrahigh molecular weight polyethylene (UHMWPE) and carbon black (CB) powders, as well as UHMWPE and CB powder mixtures of varying percentages was performed using field emission scanning electron microscopy (FESEM). Quantitative structure and friction analysis using atomic force microscopy (AFM) was performed on cryoultrasectioned block surfaces of compression-molded CB/UHMWPE composite. In addition, the mechanical properties of the composites were quantified using tensile testing, and the force dependence of the electrical properties was examined under dynamic compressive loading.     

Mechanical characterization of micro/nanoscale structures for MEMS/NEMS applications using nanoindentation techniques

Mechanical properties of micro/nanoscale structures are needed to design reliable micro/nanoelectromechanical systems (MEMS/NEMS). Micro/nanomechanical characterization of bulk materials of undoped single-crystal silicon and thin films of undoped polysilicon, SiO(2), SiC, Ni-P, and Au have been carried out. Hardness, elastic modulus and scratch resistance of these materials were measured by nanoindentation and microscratching using a nanoindenter. Fracture toughness was measured by indentation using a Vickers indenter. Bending tests were performed on the nanoscale silicon beams, microscale Ni-P and Au beams using a depth-sensing nanoindenter. It is found that the SiC film exhibits higher hardness, elastic modulus and scratch resistance as compared to other materials. In the bending tests, the nanoscale Si beams failed in a brittle manner with a flat fracture surface. The notched Ni-P beam showed linear deformation behavior followed by abrupt failure. The Au beam showed elastic-plastic deformation behavior. FEM simulation can well predict the stress distribution in the beams studied. The nanoindentation, scratch and bending tests used in this study can be satisfactorily used to evaluate the mechanical properties of micro/nanoscale structures for use in MEMS/NEMS.     

Topography and nanomechanical properties of tribochemical films derived from zinc dialkyl and diaryl dithiophosphates

In this paper we present recent results from an on‐going effort to characterize the nanomechanical properties of a variety of tribochemical, antiwear films through the use of modern scanning probe techniques. The two types of antiwear wear films studied, derived from zinc dialkyl dithiophosphate (alkyl ZDDP) and zinc diaryl dithiophosphate (aryl ZDDP), were chosen because they possess significantly different wear characteristics. High resolution AFM topographic images showed significant differences between the two types of films. More interestingly, high resolution imaging and quantitative mechanical properties testing using the interfacial force microscope (IFM), revealed different elastic and plastic properties between the two types of films; in addition each type of film possessed several distinct regions with respect to mechanical properties. The maximum values for elastic modulus and hardness were located on the highly loaded regions of the alkyl ZDDP films which exhibited the best tribological performance. In contrast, the aryl ZDDP films, which exhibited poorer antiwear behaviour, were devoid of such resilient regions. Our results correlate the macroscopic wear behavior of the tribochemical films to differences in the mechanical properties on a nanometer scale. This revised version was published online in July 2006 with corrections to the Cover Date.     

Elastohydrodynamic lubrication analysis of ultra-high molecular weight polyethylene hip joint replacements under squeeze-film motion

Elastohydrodynamic lubrication was analysed under squeeze-film or normal approach motion for artificial hip joint replacements consisting of an ultra-high molecular weight polyethylene (UHMWPE) acetabular cup and a metallic or ceramic femoral head. A simple ball-in-socket configuration was adopted to represent the hip prosthesis for the lubrication analysis. Both the Reynolds equation and the elasticity equations were solved simultaneously for the lubricant film thickness and hydrodynamic pressure distribution as a function of the squeeze-film time was solved using the Newton-Raphson method. The elastic deformation of the UHMWPE cup was calculated by both the finite element method and a simple equation based upon the constrained column model. Good agreement of the predicted film thickness and pressure distribution was found between these two methods. A simple analytical method based upon the Grubin-Ertel-type approximation developed by Higginson in 1978 [1] was also applied to the present squeeze-film lubrication problem. The predicted squeeze-film thickness from this simple method was found to be remarkably close to that from the full numerical solution. The main design parameters were the femoral head radius, the radial clearance between the femoral head and the acetabular cup, and the thickness and elastic modulus for the UHMWPE cup; the effects of these parameters on the squeeze-film thickness generated in current hip prostheses were investigated.     

Nanomechanical characterization of multilayered thin film structures for digital micromirror devices

The digital micromirror device (DMD), used for digital projection displays, comprises a surface-micromachined array of up to 2.07 million aluminum micromirrors (14 μm square and 15 μm pitch), which switch forward and backward thousands of times per second using electrostatic attraction. The nanomechanical properties of the thin-film structures used are important to the performance of the DMD. In this paper, the nanomechanical characterization of the single and multilayered thin film structures, which are of interest in DMDs, is carried out. The hardness, Young's modulus and scratch resistance of TiN/Si, SiO₂/Si, Al alloy/Si, TiN/Al alloy/Si and SiO₂/TiN/Al alloy/Si thin-film structures were measured using nanoindentation and nanoscratch techniques, respectively. The residual (internal) stresses developed during the thin film growth were estimated by measuring the radius of curvature of the sample before and after deposition. To better understand the nanomechanical properties of these thin film materials, the surface and interface analysis of the samples were conducted using X-ray photoelectron spectroscopy. The nanomechanical properties of these materials are analyzed and the impact of these properties on micromirror performance is discussed.     

Mechanical, thermal and tribological characterization of a UHMWPE film reinforced with carbon nanotubes coated on steel

Ultra-high molecular weight polyethylene (UHMWPE) coatings on steel substrate were reinforced with 0.05, 0.1 and 0.2 wt% of plasma treated single-walled carbon nanotubes (SWCNTs) to improve their mechanical, thermal and tribological properties. Nanoindentation results showed that the addition of SWCNTs up to 0.2 wt% to the UHMWPE film significantly improved the mechanical properties such as hardness (∼66%) and elastic modulus (∼58%). Wear durability of the reinforced coating increased significantly (more than two orders of magnitude) though with a slight increase in the coefficient of friction (from ∼0.08 for pristine UHMWPE film to ∼0.16 for the nanocomposite).     

Pattern abrasion of ultra-high molecular weight polyethylene: Microstructure reconstruction of worn surface

The friction and wear behavior of ultra-high molecular weight polyethylene (UHMWPE) sliding against bearing steel (AISI 52100) in a ring-on-block contact mode under the lubrication of aqueous solution of 3.5% NaCl was evaluated. The worn polymer surfaces were analyzed by means of three dimensional profiling, atomic force microscopy, Polarized Raman microanalysis, field emission scanning electron microscopy, and nanoindentation testing. It was found that unusual wavelike abrasion patterns were formed on the worn surface of UHMWPE under properly selected sliding conditions. In the presence of plowing effect, the molecular chains of UHMWPE and short-rod like microcrystalline grains of abrasion pattern were both further oriented along the plowing direction and became tiny and dense owing to microstructure reconstruction. Resultant microstructurally reconstructed worn surface of UHMWPE had a higher nanoindentation hardness and modulus as well as increased wear resistance.     

青年与老年手指甲表面形貌、成分与力学性能的实验分析

应用红外光谱仪、场发射扫描电镜、差示扫描热量仪、原位纳米力学测试系统对青年(20~25岁)与老年(70~75岁)指甲的表面结构、形貌、水含量及力学性能进行了实验分析。结果表明:与青年组成员指甲相比,老年组成员指甲的PO 2、C-O、CH 2与CONH基团的峰位向高波数移动;老年组成员指甲表面比青年组成员指甲粗糙并表现出明显的纵向纹理;尽管其总含水量与青年组成员指甲相当,但老年组成员指甲结合水的含量比青年组成员指甲的低;老年组成员指甲的硬度与约化弹性模量均高于青年组成员指甲相应对比量,因此,老年组成员指甲在划痕实验中显示出更好的耐磨性,但在较大载荷时出现明显的裂纹。     

Performance assessment of microwave treated WC insert while turning AISI 1040 steel

This study attributed to post treatment of tungsten carbide (WC) inserts using microwave irradiation. Tungsten carbide inserts were subjected to microwave radiation (2.45 GHz) to enhance its performance in terms of reduction in tool wear rate, cutting force surface roughness and improvement in tool life. Performance of tungsten carbide insert is very much affected by machine operating parameters i.e. speed, feed and depth of cut. An attempt has been made to investigate the effects of machining parameters on microwave treated tool inserts. This paper describes the comparative study of machining performance of untreated and microwave treated WC tool inserts used for turning of AISI 1040 steel. Machining performance has been evaluated in terms of flank wear, cutting force, surface roughness, tool wear mechanisms. Critical examinations of tool wear mechanisms and improvements in metallurgical properties such as microstructural change, phase activation of WC grains were identified using scanning electron microscope (SEM). Results obtained from the turning using the microwave treated tool inserts showed a significant reduction tool wear thereby enhancing the surface quality of workpiece.     

超高分子量聚乙烯材料的边界润滑特性研究

在研究人工关节材料超高分子量聚乙烯(Ultra-high Molecular Weight Polyethylene，UHMWPE)磨损机理时，考虑了表面载荷引起的变形和应力状态，运用有限元技术，采用液-力耦合方法，分析了组织液对裂纹扩展的影响以及骨移植后接触磨损机理。结果表明：裂纹顶部区域符合线弹性断裂机理，这有助于更好地了解骨移植后接触区的磨损机理。