A1025. CHAIN ENTANGLEMENTS AND UHMWPE WEAR PERFORMANCE

Abstract

Orthopaedic grade ultra-high molecular weight polyethylene (UHMWPE) remains the preferred material for one of the bearing surfaces in total joint prostheses because of its high wear resistance and proven biocompatibility. Since the 1970s, UHMWPE has served as the only widely used bearing material for articulation with metallic components in total knee arthroplasty (TKA). However, polyethylene-related total knee failures have limited the lifetime of total knee joint replacements. The present study is focused on improving material integrity and reducing the probability of material failure. The hypothesis examined here is that there is a correlation between material failure of UHMWPE knee-joint components and the precise time-temperature history employed during fabrication, due to their strong effect on interparticle cohesion. The presence of fusion defects due to incomplete consolidation and incomplete polymer self-diffusion has been implicated in the failure of UHMWPE joints [1, 2]. Computer-aided methodology used in this study allowed quantitative prediction and optimisation of the extent of interparticle cohesion to ensure that inter-particle boundaries are of high integrity during moulding [3]. The current study has investigated the correlation between inter-particle cohesion governed by reputation theory and wear performance.

We have investigated the wear performance of direct compression moulded UHMWPE plates with different degree of inter-particle diffusion. Direct compression moulding was used in the present study because of its uniformly excellent surface finish which is better than machined surfaces. UHMWPE plates (44×24×3mm) were direct compression moulded using GUR1050 powder (Ticona). Various moulding temperature (e.g. 145°C, 150°C, 175°C) and dwell time (e.g. 15mins and 30mins) were investigated.

The wear tests were carried out at 37°C using a Durham four-station multidirectional pin-onplate machine, which generates both reciprocating and rotating motions simultaneously. The material combination of the flat-ended metallic indentors loaded against UHMWPE plates was constructed to mimic conformal contact conditions in knee prostheses. The articulating surfaces were lubricated using 25% diluted bovine serum. Meanwhile the experimental method was validated by evaluating the wear generation under the conventional configuration (i.e. UHMWPE pins on metal plates); results were comparable with the data in the literature [4].

For the direct compression moulded UHMWPE plates, experimental wear factors were determined and found to correlate well with numerically calculated degree of inter-particle diffusion. Increasing moulding temperature and dwell time decreased the wear factors and increased inter-particle diffusion. Surface structures were characterised before and after every 0.5 million cycles. The observed surface features on UHMWPE plates in ESEM and optical microscopy is very similar to those in retrieved knee prostheses [5] and those found in our own recent work with knee wear simulator testing.