NOVEL 3D MAPPING OF WEAR PATCHES FOR METAL ON METAL (MOM) WEAR ASSESSMENT USING HIGH RESOLUTION OPTICAL TECHNIQUE

Abstract

Retrieval analysis offers a direct insight into in vivo wear mechanisms. However, the 3D measurement of wear patch characteristics on spherical highly reflective bearings has been difficult. An instrument based on an optical technique has been developed over the past 3 years. It is capable of scanning metallic head and cup in a single measurement, within minutes, at a resolution of 20 nm. From the cloud of 3D points obtained during scanning (typically 35,000 To 1,000,000), a 3D image of the measured part can be obtained. The associated computer program allows for sphericity, roughness, radius and local radius to be calculated, and surface maps of the 3D model can easily be plotted.

Both head and cup of two failed MoM resurfacing devices, a wear simulator test couple and intact components were analysed using the new technique. A successful McKee Farrar head (20 years in vivo) was also scanned. Results were compared with traces obtained on a Mitutoyo RA 300 roundness machine (resolution 0.01 microns).

3D maps of the bearing surfaces of MoM devices were obtained. The maximum linear wear values on heads were 2.5 microns, 99 microns 53.5 microns and 298 microns for the simulator sample, the McKee Farrar head and the two failed resurfacing devices respectively. The corresponding maximum linear wear values on cups were 11 microns, 529 microns and 645 microns for the simulator sample and the two failed resurfacing devices respectively. These results were in good agreement with results obtained on the Mitutoyo machine. Contrary to other worn samples, the two latter cups showed that the cup had worn on the edge of the bearing surface. This resulted in an oval shaped wear patch on the head. For the McKee Farrar device and the simulator device, the wear patch was away from the edge and the outline of the wear patch was circular in shape.

This novel technique has allowed for high resolution 3D mapping of the full bearing surfaces on successful McKee Farrar device and on more recent resurfacing devices. Further studies are required. However, the results suggest that component positioning is paramount to wear performance of metal on metal devices.