METAL ON METAL BEARING WEAR OF FEMORAL HIP ORTHOPAEDIC IMPLANTS PRODUCED IN COBALT CHROMIUM MOLYBDENUM ALLOY

Abstract

The ‘first generation’ Metal on Metal bearing devices was typically produced from cast, high carbon CoCrMo alloy and was in the as-cast condition. They exhibited course, hard primary, and block carbides supported by a softer matrix material. This bi-phasic condition has been verified through reported literature and forensic scientific studies of ‘long-term survived’ retrieved ‘first generation’ devices. The as-cast microstructure of CoCrMo alloys possesses superior wear resistance to the microstructures formed following post cast thermal treatments. It has been well reported that the improvement of mechanical properties, such as tensile or fatigue strength, can be achieved through the thermal treatment of this alloy. Thermal treatments of this alloy have been found to alter its’ microstructure with a significant modification to the carbide phase morphology. The modifications vary with a tendency for a refinement of the carbide size through dissolution of the chromium and molybdenum through solid state solution. Through the examination of the wear patterns of retrieved devices and wear testing of this material in its’ various microstructural conditions, it has been shown that modifications to the carbide morphology, to achieve improved mechanical properties, reduces its’ bio-tribological properties/performance leading to a lower wear resistance. The as-cast carbide morphology is the most mechanically stable condition and with its’ volume fraction, reduces the potential for adhesive wear of the matrix through ‘matrix to matrix’ contact of the two opposing bearing surfaces. It has been reported that abrasive wear is the typical mechanism for metal on metal bearings due to the generation of ‘third body’ particles from carbide asperity tips fracturing during the initial ‘running-in’ period [typically 500k to 1M cycles]. After this stage the carbides become almost level with the surrounding softer matrix material with ‘third body’ scratches dominating the surface topography. Evidence of surface pitting on ‘first generation’ devices [McKee Farrar and Muller] and modern high carbon wrought devices [Metasul] has been attributed to adhesive/fatigue wear following surface-to-surface contact. Therefore, in microstructural conditions, where there is a reduced carbide volume fraction, or no carbides present, wear resistance is reduced. To test this hypothesis two wear tests have been carried out on CoCrMo samples produced from the same chemistry alloy, with varying microstructures, using Calowear [abrasive] and Pin on Dist [adhesive] tests. The as-cast microstructural condition was determined to have the lowest wear coefficient [k=mm3/Nm] in both tests, however statistical significance at 90% confidence interval was only confirmed in the Calowear Test. Examination of wear scars confirmed the mechanical stability of the as-cast carbide phase. It is noted, however that there are papers which have been published offering a divergence of opinion to this hypothesis and which have been considered by this author.