Abstract
The advantages of modularity in both primary and revision hip surgery are well documented, and have been at the heart of innovation in hip implant design over the last two decades. Modularity allows us to address version, length and offset issues and to restore optimal hip biomechanics. There are, however, increasing clinical concerns associated with the failure of taper junctions. The use of large femoral heads and modular stems are now considered major risk factors for taper corrosion. I will summarise our laboratory and retrieval data on taper design and tribology in order to put in perspective the clinical use of modularity in hip arthroplasty.
Modular junctions rely on a frictional interlock. The engagement obtained and resulting micromotion is strongly influenced by taper size, taper length/engagement, material, surface finish, neck length and offset. In our quest for thinner femoral necks, greater offsets and bigger femoral heads, we have inadvertently created an environment that can generate fretting corrosion at modular junctions and leads to premature implant failure.
An inverted hip replacement setup was used similar to the specified ASTM test (ASTM F1875–98). Twenty-eight millimeter Cobalt Chrome (CoCr) femoral heads were coupled with either full length (standard) or reduced length (mini) 12/14 Titanium (Ti) stem tapers. These Ti stem tapers had either a rough or smooth surface finish whilst all the head tapers had a smooth finish. Wear and corrosion of taper surfaces were compared following a 10 million loading cycle. The surface roughness parameters on the head taper were significantly increased when the head-stem contact area was reduced. Similarly, the surface roughness parameters on the head taper were significantly increased when rough stem tapers were used. With rough male tapers the CoCr head taper became circumferentially ridged with distinct areas of pitting corrosion similar to that seen on some retrievals. In these tests similar surface morphology to that on retrieved femoral heads was seen on the female head taper.
Thirty-six millimeter CoCr femoral heads were also coupled with either a CoCr or Ti stem with 12/14 tapers all with smooth finish. Increasing perpendicular horizontal offsets in the sagittal plane created incremental increases in torque. A proportional relationship between torque and corrosion was observed for both CoCr-CoCr and CoCr-Ti material combinations.
In-vitro studies were used to evaluate the role of: taper size, angle mismatch, surface finish, and manufacturing tolerances on taper engagement. In-vitro loading analysis was performed to determine the bearing friction experienced by the taper connection. The component materials analysed were CoCr and Ti for stem design and CoCr/CoCr, ceramicized metal/CoCr, and CoCr/Ti for head/neck tapers. The high performance combinations included tapers with larger diameters, rougher surface finish, tighter tolerances and a proximal locking location. Loading studies demonstrate a 15 – 31% reduction in frictional torque (for 28, 36 and 40mm head sizes) using the ceramicized metal/XLPE couples compared to CoCr/XLPE couples.
Retrieval studies were conducted to assess taper corrosion using the Goldberg system and SEM analysis. Two hundred-nine taper surfaces, with in-vivo time varying from 1 week and 10 years, were analysed showing that ceramicized metal femoral heads have a lower corrosion score compared to CoCr femoral heads.
Understanding the key design and surgical factors that drive the performance of taper junctions is vital for the surgical community. There is a body of knowledge that supports appropriate taper use / modularity to help surgeons deal with complex situations. We must be careful not throw the baby out with the bathwater.
