Radiographic assessment of the cement mantle thickness of the femoral stem in total hip replacement: a case study of 112 consecutive implants

The results are reported of a radiographic study of cement mantle thickness in 112 consecutive primary hip replacements. Measurements were made by three observers of the apparent cement thickness medially and laterally using standard anterior-posterior radiographs. The average cement thickness was 3.2 mm, which is 1.2 mm greater than the size difference between the broach and the prosthesis, and was in the range 2-5 mm in 67 per cent of all measurement points. This has significance for the design of instrumentation to prepare the femoral cavity to give a defined cement mantle thickness. There was a greater cement mantle thickness proximally than distally. In 95 cases it was possible to determine the orientation of the stem within the cement mantle, which showed an even distribution between varus and valgus orientation; 49 per cent were within 1 degree of neutral and only one case was more than 5 degrees from neutral.     

The stability of the femoral component of a minimal invasive total hip replacement system

In this study, the initial stability of the femoral component of a minimal invasive total hip replacement was biomechanically evaluated during simulated normal walking and chair rising. A 20 mm diameter canal was created in the femoral necks of five fresh frozen human cadaver bones and the femoral heads were resected at the smallest cross-sectional area of the neck. The relatively short, polished, taper-shaped prostheses were cemented centrally in this canal according to a standardized procedure. A servohydraulic testing machine was used to apply dynamic loads to the prosthetic head. Radiostereophotogrammetric analysis was used to measure rotations and translations between the prosthesis and bone. In addition, the reconstructions were loaded until failure in a static, displacement-controlled test. During the dynamic experiments, the femoral necks did not fail and no macroscopical damage was detected. Maximal values were found for normal walking with a mean rotation of about 0.2 degrees and a mean translation of about 120 microm. These motions stabilized during testing. The mean static failure load was 4714 N. The results obtained in this study are promising and warrant further development of this type of minimal invasive hip prosthesis.     

A comparative study of the performance of metallic and ceramic femoral head components in total replacement hip joints

Arthroplasty represents an outstanding twentieth century achievement in orthopaedic surgery. However, in recent years polyethylene wear debris has been linked to the loosening process in implants and there is considerable interest in reducing the severity of wear through the introduction of improved materials and alternative designs of total replacements joints. During the past twenty years or so, ceramic components have been introduced, either as ceramic-on-ceramic or as ceramic-on-polymer combinations of sliding pairs of materials and in this paper a tribological appraisal is made of the performance of the latter combination in relation to the long established metal-on-polymer arrangement. The basic mechanisms of wear in total replacement joints are considered and attention is drawn to the role of creep in determining the initial penetration of the femoral head into the polyethylene acetabular cup. Laboratory and clinical studies of the tribological characteristics of current forms of implants are then reviewed.     

Understanding initiation and propagation of fretting wear on the femoral stem in total hip replacement

The femoral stem–bone cement interface in total hip replacement is supposed to experience low amplitude oscillatory micromotion under physiological loading, consequently leading to fretting wear on the stem surface, which nowadays is considered to play an important part in the overall wear of cemented prosthesis. However, initiation and propagation of fretting wear has been poorly documented and a better understanding concerning this issue has not been established as yet. This present study, on the basis of a profound surface investigation of a polished Exeter V40? femoral stem and Simplex P bone cement obtained from an in vitro wear simulation, demonstrated that the edges of the micropores in the cement surface matched pretty well to the boundaries of the worn areas on the stem surface. This would indicate that these micropores contributed significantly to the fretting process at the stem–cement interface.     

A simulator study of friction in total replacement hip joints.

Frictional behaviour of 22 different femoral head-acetabular cup combinations was studied on a new servo-hydraulic microcomputer-controlled hip joint simulator using various flexion-extension angle and superior-inferior load set value waveforms and using distilled water at 37 +/- 1 degrees C as lubricant. Six different head materials were included in the study, whereas all cups were ultra-high molecular weight polyethylene (UHMWPE). Most head-cup combinations studied are commercially available. No distinctly superior joint design can be pointed out, but the frictional behaviour of alumina ceramic against UHMWPE proved overall most favourable (mu min was 0.02), whereas that of non-ion-implanted titanium alloy Ti-6Al-4V against UHMWPE proved strikingly poor (mu max was 0.15). The lowest frictional torque was in 22 mm joints, but frictional torque did not always increase straightforwardly with increasing diameter of the femoral head. The measurements form an extensive comparison between a wide variety of head-cup combinations. The simulator is apparently a useful instrument in the study of frictional behaviour of new designs, materials, surface treatments and coatings that are frequently introduced.     

The contribution of the micropores in bone cement surface to generation of femoral stem wear in total hip replacement

Although cemented total hip replacement has long been recognized as a situation that can lead to wear, the wear generated on the femoral stem has not been well documented, especially with regard to how this wear is initiated and propagated. This present work aimed to further investigate this issue based on a comprehensive study on surface morphology of the femoral stem and the bone cement, which were collected from seven in vitro wear simulations. It was shown that the wear locations on the stem surface compared well with the results of retrieval studies, and the boundaries of the worn areas matched well the edges of the micropores present in the bone cement surface. This indicated that the micropores could potentially contribute to the generation of femoral stem wear. In addition, metallic debris was detected around the micropores from the simulation with increased loading cycles. However, no evidence of macro-cracks was observed across the cement mantle in spite of the presence of micro-cracks initiated at the edge of the micropores. This study demonstrated a possible cause for progression of femoral stem wear and it may have an important bearing on the long term durability of cemented hip prosthesis.     

Head replacement, head rotation, and surface damage effects on metal-on-metal total hip replacements: a hip simulator study

The possibility of replacing the femoral head alone, in either solid or articular surface replacement form, during revision operations on metal-on-metal total hip replacements remains an attractive feature of such implants. In the present investigation, laboratory simulator studies of the influence upon volumetric wear of inserting a new femoral head, of introducing some head rotation, and of damaging the femoral head by scratches have all been explored. New and rotated heads both involve an additional running-in period, but the experimental studies show that the volumetric wear associated with this process is less than the initial running-in wear. The beneficial effects upon volumetric wear of small clearances have been confirmed, while the processing of high-carbon Co-Cr-Mo materials appears to be much less influential. Scratches did not affect wear as much as head replacement or head rotation, but the ongoing wear rates were somewhat higher.     

Analysis of debris from brushing the femoral canal with a plastic brush--a potential cause of loosening in total hip replacement

The generation of submicrometre sized polyethylene particles has been shown to be one of the major causes of osteolysis, loosening and failure of total replacement joints. It has been reported that intramedullary brushing of the femoral canal with polymer brushes prior to total hip arthroplasty results in the release of polymer particles into the femoral canal. The aim of this study was to isolate and characterize these particles on the basis of morphology and size and to determine whether these particles may play a role in osteolysis and loosening of the total hip prostheses. It was found that the majority of the particles shed by the polymer brushes were submicrometre in size and were similar in morphology to UHMWPE wear particles isolated from periprosthetic tissues. In addition, the majority of the particles released by the brushes were in the biologically active size range (0.1-10 microns), and may contribute to osteolysis and loosening of hip prostheses.     

Laboratory wear tests and clinical observations of the penetration of femoral heads into acetabular cups in total replacement hip joints: I: Charnley prostheses with polytetrafluoroethylene acetabular cups

A quarter of a century has now elapsed since the late Professor Sir John Charnley introduced his low friction arthroplasty of the hip based on a stainless steel femoral component and an unfilled polytetrafluoroethylene (PTFE) acetabular cup. The advantages of the very low friction resulting from the use of PTFE and a femoral head of diameter 22 mm were unfortunately outweighed by a very rapid penetration of the femoral head into the acetabular cup. Charnley abandoned the use of PTFE after some 3 years and 300 operations and subsequent measurements revealed a penetration rate of 2.26 mm year^?1. In 1962 he adopted ultrahigh molecular weight polyethylene as the socket material and this material is now used almost exclusively in total replacement joints.In this paper we report further laboratory wear studies of PTFE on stainless steel in disc machines and compare the laboratory wear factors with those deduced from clinical observations. Charnley's clinical penetration rates have been analysed in terms of Paul's loading cycles for steady walking and measurements of the walking activity of elderly patients by Wallbridge and Dowson.It is shown that the wear factor for PTFE and stainless steel is about 3 × 10^?5mm³N^?1m^?1 and that there is excellent agreement between the mean value obtained from a variety of laboratory experiments involving environments of atmospheric air, distilled water, bovine synovial fluid and Ringers' solution with various counterface roughnesses and the wear factors derived from clinical observations.     

A study of the wear of some materials in connection with total hip replacement

Failure of total hip prostheses due to wear is examined. It is concluded that wearing out of these devices should not be a problem. However, it is desirable to look for materials of improved wear resistance due to possibilities of long-term response to wear debris.A series of experiments is described to evaluate the wear resistance of candidate materials on an annular wear tester. The results indicate that the wear resistance of ultra high molecular weight polyethylene may be improved by increase in molecular weight, by irradiation or by the use of fillers. Pyrolytic carbon containing silicon is also a good candidate.     

Automated in-vitro testing of orthopaedic implants: a case study in shoulder joint replacement

This investigation presents the design and preliminary validation of a single station simulator with biaxial motion and loading designed to mimic the kinematics of the glenohumeral joint during arm abduction in the scapular plane. Although the design of the glenoid holder allows the glenoid component to translate in all three axes, it is primarily loaded axially, which brings it into contact with the oscillating humeral head, but is also loaded superiorly to simulate common subluxation of the humeral head. Simulating arm abduction in the scapular plane simplifies component alignment and removes the need for anterior-posterior loading, thereby creating a stable joint without the need to simulate capsular constraints. In this more physiologically accurate simulator design, the load and motion profiles influence the contact kinematics, but the wear path is ultimately determined by the conformity and constraint designed into the bearing couple. The wear data are determined and correlated with clinically retrieved glenoid components, as well as previously reported in-vitro studies, thus verifying use of the simulator in testing alternative materials and designs. The key design features, as well as the improvements proposed through this study, can be incorporated into the design of test fixtures for any other orthopaedic implant such as the hip, knee, spine, elbow, and finger.     

Femoral strain adaptation after total hip replacement: a comparison of cemented and porous ingrowth components in canines

The purpose of this study was to investigate if experimental strain analysis is predictive of femoral adaptation after total hip replacement (THR). Ten large adult dogs underwent unilateral THR with identical implants. Five implants were press fit for porous ingrowth fixation, and five were cemented. Four months after surgery femora were harvested. Strain gauge rosettes were applied to the femora at eight proximal locations. Femora were compressively loaded on the head of the femur or femoral component. Strain data represented three conditions: preoperative, acutely postoperative, and four-month postoperative. The unoperated femur of each dog was used to simulate preoperative and acutely postoperative behavior of the contralateral implanted femur. Strains from each condition were compared. Transverse femoral sections were obtained through the levels of the strain gauges. Fine detailed radiographs were used to quantify morphological changes. Results showed cemented and uncemented implantations produce similar trends but different amounts of bone adaptation. Adaptations were generally consistent in direction with strain perturbations caused by implantation, but the extent of adaptation did not strongly correlate with the magnitude of perturbations. Also, there was no consistent trend towards normalization of altered strains. Results suggest that strain perturbations after THR may be mechanical triggers for morphological changes, but caution is required when predicting the extent of these changes or the autoregulatory role of strain.     

Torsional stability of a polished, collarless, tapered total replacement hip joint stem under vertical load: an in vitro investigation

The torsional stability of a polished, collarless, tapered total replacement hip joint stem has been investigated. It was believed that such a stem would show increasing torsional stability as the vertical component of load on the stem increased. The aim of the study was to examine this hypothesis by testing a number of specimens (including Exeter stems) with either a matt or polished finish, under increasing vertical load, measuring the torsional resistance of a specimen-cement construct within an outer constrained cement shell. It was concluded that stems with a polished, collarless, tapered shape showed increased torsional stability with increasing vertical load, while stems with a matt finish or a collar did not.     

The effect of femoral head diameter upon lubrication and wear of metal-on-metal total hip replacements

It has been found that a remarkable reduction in the wear of metal-on-metal hip joints can be achieved by simply increasing the diameter of the joint. A tribological evaluation of metal-on-metal joints of 16, 22.225, 28 and 36 mm diameter was conducted in 25 per cent bovine serum using a hip joint simulator. The joints were subject to dynamic motion and loading cycles simulating walking for both lubrication and wear studies. For each size of joint in the lubrication study, an electrical resistivity technique was used to detect the extent of surface separation through a complete walking cycle. Wear of each size of joint was measured gravimetrically in wear tests of at least 2 x 10(6) cycles duration. Joints of 16 and 22.225 mm diameter showed no surface separation in the lubrication study. This suggested that wear would be proportional to the sliding distance and hence joint size in this boundary lubrication regime. A 28 mm diameter joint showed only limited evidence of surface separation suggesting that these joints were operating in a mixed lubrication regime. A 36 mm diameter joint showed surface separation for considerable parts of each walking cycle and hence evidence of the formation of a protective lubricating film. Wear testing of 16 and 22.225 mm diameter metal-on-metal joints gave mean wear rates of 4.85 and 6.30 mm3/10(6) cycles respectively. The ratio of these wear rates, 0.77, is approximately the same as the joint diameters ratio, 16/22.225 or 0.72, as expected from simple wear theory for dry or boundary lubrication conditions. No bedding-in was observed with these smaller diameter joints. For the 28 mm diameter joint, from 0 to 2 x 10(6) cycles, the mean wear rate was 1.62 mm3/10(6) cycles as the joints bedded-in. Following bedding-in, from 2.0 x 10(6) to 4.7 x 10(6) cycles, the wear rate was 0.54 mm3/10(6) cycles. As reported previously by Goldsmith et al. in 2000 [1], the mean steady state wear rate of the 36 mm diameter joints was lower than those of all the other diameters at 0.07 mm3/10(6) cycles. For a range of joints of various diameters, subjected to identical test conditions, mean wear rates differed by almost two orders of magnitude. This study has demonstrated that the application of sound tribological principles to prosthetic design can reduce the wear of metal-on-metal joints, using currently available materials, to a negligible level.     

Comparative study on the wear behaviour of different conventional and cross-linked polyethylenes for total hip replacement

In this study, five different types of conventional and cross-linked polyethylene (XLPE) (γ-sterilised PE GUR1020, EtO-sterilised PE GUR1020, γ-sterilised PE GUR1050, EtO-sterilised XLPE GUR1020, EtO-sterilised XLPE GUR1050) acetabular cups were tested on a hip joint simulator run for 5 million cycles in order to compare the relative long-term wear resistance in relation to material properties (PE grade, conventional or cross-linked) and sterilisation method (EtO treatment or γ-irradiation).Gravimetric measurements revealed significant differences between the wear behaviours of the five sets of acetabular cups. Weight loss was found to decrease along the series: γ-sterilised PE GUR1020>EtO-sterilised PE GUR1020>γ-sterilised PE GUR1050>EtO-sterilised XLPE GUR1050>EtO-sterilised XLPE GUR1020. The wear results were discussed in relation to the crystallinity degree of the cups which was determined by micro-Raman spectroscopy coupled to partial least-squares analysis. Within both conventional and cross-linked PE series, it appeared that higher crystallinity samples (i.e. γ-sterilised PE GUR1020 and EtO-sterilised XLPE GUR1050, respectively) were characterised by higher wear rates. The higher weight loss observed for PE GUR1020 was explained in relation to its lower molecular weight with respect to PE GUR1050. Raman analysis showed that wear testing did not significantly modify the crystallinity degree of any of the tested acetabular cups. The most worn cup, i.e. γ-sterilised PE GUR1020, appeared the most homogeneously polished upon wear testing, as confirmed by the lowest standard deviation associated to the crystallinity value recorded in the centre of the cup. The results of this investigation have clearly shown a dramatic wear reduction in favour of the cross-linked polyethylene.     

Optimizing the configuration of cement keyholes for acetabular fixation in total hip replacement using Taguchi experimental design

Cement fixation of the acetabular component is increasingly recognized as a common site of loosening when hip replacements fail. Cement keyholes drilled into the acetabulum have been recommended to improve this fixation but little is known of the optimum positions or sizes of these holes. This study investigates the diameter, depth and number of keyholes to be drilled to maximize the failure torque in a model system. A Taguchi experimental design was used to identify the most significant factors and to predict the best configuration of keyholes within the constraints of the experimental test rig. One hole at each of the pubic, iliac and ischial sites, of 12 mm diameter and 6 mm depth, was found to be the optimum configuration. The failure torque was most strongly dependent on the hole diameter in the pubic region, decreased with increasing hole depth and was not sensitive to the number of holes.     

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).     

Analysis and modelling of wear of cobalt-chrome alloys in a pin-on-plate test for a metal-on-metal total hip replacement

The complex interaction between wear and bearing surfaces of two contacting solids was investigated in this study, with particular reference to the use of metal-on-metal material combinations for artificial hip joint replacements. The contact mechanics model was coupled with the wear model and solved simultaneously as a function of time for a simple case of a uniaxial pin-on-plate wear test. Both a spherical pin and a flat-ended spherical pin were considered. It was shown that the contact pressure between the pin and the plate was substantially reduced by the wear process, particularly during the initial running-in period and for the spherical pin. The theoretical prediction of the worn profiles of the pin and the plate was found to be in good agreement with previous experimental measurements by Tipper et al. in 1999.     

On the influence and optimisation of cutting parameters in finishing of metallic femoral heads of hip implants

Roughness and sphericity are two important factors affecting friction and lubrication performance of femoral heads of hip implants. Precision finishing of femoral heads is therefore crucial. This paper presents the effect and optimisation of key machining parameters in finish turning of metallic femoral heads, with an aim to achieve the best surface roughness and sphericity. Three important machining variables—cutting speed, feed rate and depth of cut—were considered. According to Taguchi methodology, a factorial design of experiments was planned to capture the effect of machining variables. A series of single-pass finish turning tests was conducted on a 28-mm femoral head made of biomedical grade stainless steel AISI 316 L by using tungsten carbide inserts. We used the analysis of variance (ANOVA) to elucidate the influence of the dominant parameters, which led to derive a regression model and response surface to estimate the desired machining responses. The results suggest that, among all cutting parameters, feed rate affects significantly surface roughness, while both feed rate and depth of cut are the dominant factors impacting markedly sphericity. Using desirability function-based criteria, single response and multiresponse optimisations were performed to determine an optimum combination of machining parameters. The objective was to maximise the desirability under the given range of parameters. Optimisation results show that cutting speed of 280.02 m/min, feed rate of 0.1 mm/rev and depth of cut of 0.2 mm are the optimum set, which is expected to provide minimum surface roughness and sphericity of the finished femoral heads. The parameters are thus expected to minimise further polishing time and improve manufacturing productivity.     

An in vitro study of the reduction in wear of metal-on-metal hip prostheses using surface-engineered femoral heads

Although the wear of existing metal-on-metal (MOM) hip prostheses (1 mm3/10(6) cycles) is much lower than the more widely used polyethylene-on-metal bearings, there are concerns about the toxicity of metal wear particles and elevated metal ion levels, both locally and systemically, in the human body. The aim of this study was to investigate the possibility of reducing the volume of wear, the concentration of metal debris and the level of metal ion release through using surface-engineered femoral heads. Three thick (8-12 microm) coatings (TiN, CrN and CrCN) and one thin (2 microm) coating (diamond-like carbon, DLC), were evaluated on the femoral heads when articulating against high carbon content cobalt-chromium alloy acetabular inserts (HC CoCrMo) and compared with a clinically used MOM cobalt-chromium alloy bearing couple using a physiological anatomical hip joint simulator (Leeds Mark II). This study showed that CrN, CrCN and DLC coatings produced substantially lower wear volumes for both the coated femoral heads and the HC CoCrMo inserts. The TiN coating itself had little wear, but it caused relatively high wear of the HC CoCrMo inserts compared with the other coatings. The majority of the wear debris for all half-coated couples comprised small, 30 nm or less, CoCrMo metal particles. The Co, Cr and Mo ion concentrations released from the bearing couples of CrN-, CrCN- and DLC-coated heads articulating against HC CoCrMo inserts were at least 7 times lower than those released from the clinical MOM prostheses. These surface-engineered femoral heads articulating on HC CoCrMo acetabular inserts produced significantly lower wear volumes and rates, and hence lower volumetric concentrations of wear particles, compared with the clinical MOM prosthesis. The substantially lower ion concentration released by these surface-engineered components provides important evidence to support the clinical application of this technology.