INTRODUCTION. There is increasing worldwide interest in the assessment of wear in explanted hip components. This is due is part to high profile failures of orthopaedic components in the US, whilst in the UK hip resurfacings have been experiencing a higher than expected failure rate. The reasons for these failures are not well understood, with data from the NJR suggesting the 43% of MoM resurfacing failures are unexplained. Wear analysis is a vital tool in determining failure mechanisms and ultimately improving the longevity of joint replacements through improved design and manufacturing control. There are currently no relevant measurement standards for the evaluation of retrieved orthopaedic components. This paper will assess two of the most commonly used techniques namely roundness measurement and co-ordinate measurement. The advantages and disadvantages of both techniques are considered in this paper. ROUNDNESS MACHINE. The Talyrond 365 is a stylus based roundness machine. The component is located on a rotating table and the stylus measures the deviation from a perfect circle as the component is slowly rotated. The Talyrond measures a single profile to an accuracy of 30 nm and up to 72,000 data points per revolution. The air spindle has a radial accuracy of <0.02 μm and the Talymin gauge a minimum resolution of 12 nm. Individual roundness profiles can be stitched together to build up 3D cylinder maps, allowing 3D pictures of sections of explanted hip components to be generated. COORDINATE MEASURING MACHINE. Co-ordinate measuring machines (CMMs) have been widely used in manufacturing quality and research departments for a number of years and the CMM is recognised as a powerful and important tool capable of ascertaining geometric data from a component. The CMM used in this study was a Zeiss Prismo CMM (Carl Zeiss Ltd., Rugby, UK) with a probing error of 0.7 μm. Components are securely held in a chuck fixture arrangement and the dimensions of the component in the portion of the bearing that is unworn is ascertained through measurement. The initial measurements are used to produce a reverse engineered 3D CAD surface which represents the component ‘pre-wear’ surface. The surface of the component is then scanned and the deviation from this pre-wear surface is mapped. The maximum linear wear and wear volume are then calculated directly. DISCUSSION. The main advantage of CMM and Talyrond is that they are available in most metrology and measurement rooms. The CMM is a particularly versatile machine and can be used to measure any orthopaedic components. There is a need to develop a suitable Standard for both machines detailing a protocol to measure explanted hip and quantify the wear. A study is underway to measure a set of explanted hip components to allow a detailed comparison between of measurements between the Talyrond and CMM. The result of this study will be included in the paper. CONCLUSIONS. The CMM and Talyrond are both instruments suited to measuring wear of explanted hips. A full evaluation of the systems and the development of robust measurement protocol and standard would be advantageous to the orthopaedic industry

Abstract. Introduction. Several studies have reported significant cobalt(Co) and chromium(Cr) elevations in the blood of patients with total-knee-replacements (TKRs), and histological signs of metal sensitivity have been reported in up to 44% of patients undergoing revision of their TKRs. We carried out this investigation to determine the source and quantity of metal release in TKRs. Methodology. We identified all TKRs with polished CoCr trays (N=59) [Vanguard=29, Attune=4 and PFC=26]. These were analysed using peer-reviewed [coordinate-measuring-machine (CMM)] methodology to measure the volumetric wear of the polyethylene (PE) bearing surfaces and trays. The trays were analysed using 2D-profilometry (surface roughness-Ra) and 4D-microscopy. Histological and blood metal ion concentration analyses were performed. Results. The median(IQR) PE wear rate was 10(6to20) mm3/year. Microscopic analysis identified pitting on superior surface of 36(49%) trays. Ra [median (IQR)] of superior surface of pitted trays [0.076 (0.060–0.084) µm] showed a statistically significant increase (p<0.001) compared with unpitted trays [0.057(0.049–0.066) µm]. 4D-microscopy and CMM analysis estimated wear volumes of up to 2mm3 secondary to pitting. The median (range) Co and Cr concentrations were 2.5µg/l (0.2–69.4) and 1.7µg/l (0.5–12.5) respectively in 40 patients. Of the tissue samples examined in 30 patients,6 had at-least “mild”-ALVAL infiltrate. All corresponding “ALVAL” explants were found to be pitted and/or show evidence of loosening of the tray. Conclusion. This study provides further evidence that CoCr release in TKR appears to be an under-recognised cause of adverse clinical outcomes. Gross metal ion elevations occurred in association with micromotion/loosening of the tray

In an effort to understand the role of metal ion analysis and how it relates to revision surgery and implant wear, four revised MOM cases were reviewed. The first case was revised for acute infection and is representative of the low bearing wear predicted by MOM simulator studies. Two of the four cases had apparent anterior subluxation as a result of hip hyperextension occurring with long stride gaits. The last case is a true hypersensitivity response to CoCr ions. All four MOM prostheses were implanted by one surgeon and revised by the same surgeon approximately 6–8 years postoperatively. The implants had been positioned satisfactorily with inclination angles 45°–55° and anteversion angles 28°–42°. Patient A (76 y/o female) with bilateral MOM hip replacements, was revised at approximately 8 years due to infection and had moderately elevated ions at the time of revision surgery (Co = 5, Cr = 2.3, Ti = 4). Only the femoral head was retrieved in this case. Retrieval analysis identified a well defined main-wear zone and one polar stripe. The CMM indicated there was minimal wear overall (form factor = 11 μm). Patient B (33 y/o male) with bilateral MOM hip replacements, was revised at approximately 8 years due to pain, popping/catching sensations, and elevated ions (Co = 33, Cr = 17, Ti = 90). Intraoperatively, the implant was observed subluxing superiorly from the acetabular cup with anterior rotation of the leg. Both the femoral head and acetabular cup were retrieved. Retrieval analysis identified a well defined main-wear zone and multi-directional polar stripe formations similar to those reported on dislocated implants (Figure 1)[McPherson 2012, 2013]. The CMM indicated that overall wear was significant (form factor > 100 μm). Patient C (77 y/o female) was revised at approximately 6 years due to pain, suspected implant loosening, osteolytic cysts determined by CT, and highly elevated ions (co = 164, Cr = 45, Ti = 33). Intraoperatively, there was evidence of wear including darkly stained tissue and osteolytic cysts. Both the femoral head and acetabular cup were retrieved. Retrieval analysis identified a well defined main-wear zone and one polar stripe. CMM indicated considerable wear (head form factor > 200, cup form factor >300). Patient D (45 y/o female) was revised at approximately 6 years due to pain, apparent reactive response joint effusion, and moderately elevated ions (Co = 5, Cr = 6, Ti = 71). Only the femoral head was retrieved. Retrieval analysis identified a well defined main-wear zone and one polar stripe. Minimal wear was indicated by CMM (form factor = 21). These four cases demonstrate distinct failure models of MOM hips and their respective metal ion results. Due to the diversity of patient location, a variety of clinical labs were utilized for this patient population. Caution should be used in interpreting metal ion analysis, as there are still no standards. Figure 1: Retrieval analysis of stripe wear identified on femoral head from patient B. Figure 2: Femoral head from patient C showing broader polar stripe associated with anterior subluxation in comparison to narrow polar stripe found on femoral head from patient A

Introduction: One of the latest groups of replacement hip joints are known as hip resurfacings and they consist of a relatively large diameter femoral head articulating within a thin acetabular cup. Many of these devices show good short to medium term clinical results. However there are concerns over such implants including fracture of the femur and possible wear debris related reactions. Much valuable data can be learnt from explanted prostheses which have ‘failed’ and then been removed from patients. As hip resurfacing prostheses have only recently been introduced, there are relatively few such retrieval studies. Methods and materials: Nineteen femoral and acetabular components from metal-on-metal hip resurfacing prostheses were obtained at revision operations. There were eight patients who had femoral fractures and the remainder experienced worsening groin pain and a characteristic sterile effusion. There were eleven head components and four pairs of matching heads and cups. Each of these was examined using a Zeiss TSK Rond-com60A roundness measuring machine and a Mitutoyo LEGEX co-ordinate measuring machine (CMM). Out of roundness measurements were taken on three planes for each acetabular and femoral component. The CMM was used to obtain 12 traces at 30° intervals for each acetabular and femoral component, allowing areas of localised wear to be identified and the maximum wear depth to be quantified. Results: The maximum out of roundness values for the nineteen components ranged from 1.8 to 91.8 microns. A similar range of values was obtained from the CMM results. From the paired components, out of roundness was greater in the head than in the cup. All eight femoral heads which were retrieved after fracture of the femur showed out of roundness of less than 5 microns. Discussion: Both out of roundness measurements and those from the CMM provided information about the wear of the implants. For a new component, a typical out of roundness value would be no greater than 5 microns. Therefore, from the out of roundness values it was seen that the eight ‘fracture’ components showed minimal distortion or wear after removal. In contrast the remaining components, which had a minimum out of roundness of 15 microns, showed much greater wear, thus suggesting that the groin pain was associated with relatively large volumes of wear debris. CMM scans helped to identify localised areas of wear and maximum wear depths. Values in the range of < 2 microns to 164 microns have been reported previously and show good agreement with the findings of this study. Retrieved components which had been implanted at high angles of inclination and anteversion tended to show the greatest wear, implying that correct positioning in vivo is crucial to the longevity of hip resurfacing prostheses

Objectives. Wear debris released from bearing surfaces has been shown to provoke negative immune responses in the recipient. Excessive wear has been linked to early failure of prostheses. Analysis using coordinate measuring machines (CMMs) can provide estimates of total volumetric material loss of explanted prostheses and can help to understand device failure. The accuracy of volumetric testing has been debated, with some investigators stating that only protocols involving hundreds of thousands of measurement points are sufficient. We looked to examine this assumption and to apply the findings to the clinical arena. . Methods. We examined the effects on the calculated material loss from a ceramic femoral head when different CMM scanning parameters were used. Calculated wear volumes were compared with gold standard gravimetric tests in a blinded study. . Results. Various scanning parameters including point pitch, maximum point to point distance, the number of scanning contours or the total number of points had no clinically relevant effect on volumetric wear calculations. Gravimetric testing showed that material loss can be calculated to provide clinically relevant degrees of accuracy. . Conclusions. Prosthetic surfaces can be analysed accurately and rapidly with currently available technologies. Given these results, we believe that routine analysis of explanted hip components would be a feasible and logical extension to National Joint Registries. Cite this article: Bone Joint Res 2014;3:60–8

Abstract. Objectives. Impingement of total hip replacements (THRs) can cause rim damage of polyethylene liners, and lead to dislocation and/or mechanical failure of liner locking mechanisms[1]. A geometric model of a THR in situ was previously developed to predict impingement for different component orientations and joint motions of activities[2]. However, the consequence of any predicted impingement is unknown. This study aimed to develop an in-vitromethod to investigate the effects of different impingement scenarios. Method. A ProSim electro-mechanical single-station hip simulator (Simulation Solutions) was used, and the 32mm diameter metal-on-polyethylene THRs (DePuy Synthes) were assessed. The THR was mounted in an inverted orientation, and the input (motion and loading) applied simulated a patient stooping over to pick an object from the floor[3]. The impingement severity was varied by continuing motion past the point of impingement by 2.5° or 5°, and compressive load applied in the medial-lateral direction was varied from 100N to 200N. Each test condition was applied for 40,000 cycles (n=3). Rim penetration was assessed using a CMM and component separation was measured during the tests. Results. Varying the impingement severity from 2.5° to 5° increased rim penetration two-fold (by >0.05mm) and increased medial-lateral component separation three-fold (by >0.3mm) (both p<0.001). Increasing the medial-lateral load had less effect on the rim penetration and component separation, with exception of rim penetration with the higher impingement severity condition. Conclusion. The impingement severity influenced the medial-lateral component separation, suggesting that increasing the impingement severity could increase the risk of dislocation. The impingement severity, which could be predicted from geometric modelling, was also found to significantly affect rim penetration, meaning this method could be used alongside geometric modelling to predict impingement severity in a range of scenarios. Declaration of Interest. (a) fully declare any financial or other potential conflict of interest

Introduction. Highly cross-linked (HXL) polyethylene has demonstrated clinical advantages as a wear resistant acetabular bearing material in total hip arthroplasty (THA) [1]. In vitro wear testing has predicted a tenfold reduction in the wear rate of HXL polyethylene, as compared to its conventional, non-HXL counterpart [2]. To date, radiographic studies of head penetration represent the state-of-the-art in determining clinical wear of polyethylene hip liners [3]. However, as the amount of wear drops to very low levels, it becomes important to develop a precise and reliable method for measuring wear, facilitating a comparison of clinical results to expectations. This study focuses on locating and quantifying the maximum linear wear of retrieved acetabular poly liners using a coordinate measuring machine (CMM). Specifically, HXL liners are compared to a baseline of conventional, non-HXL bearings. Methods. An IRB-approved retrieval laboratory received 63 HXL acetabular bearing retrievals from 5 manufacturers with in vivo durations of 1.01–14.85 years. These were compared with 32 conventional, non-HXL controls (including gas plasma, gamma-barrier and EtO) from 3 manufacturers with in vivo durations of 1.03–20.89 years. Liners were mounted in a tripod of axial contacts with the liner face positioned in a vertical plane. Each bearing was scanned with a CMM dual-probe head, with one horizontal probe scanning the articular surface and the other scanning the non-articular, sequentially. Surface-normal wall thickness values along each latitude were calculated using a custom developed algorithm (Figure 1). Because the liners are axially symmetric as manufactured, deviation in wall thickness at a given latitude represents linear wear [4]. Results. Total wear penetration for the HXL liners ranged from 0.02 to 1.03 mm, and for the conventional, non-HXL controls ranged from 0.07 to 6.85 mm. The HXL liners had an average linear wear rate of 0.02 mm/year, compared to 0.20 mm/year for the conventional, non-HXL controls (Figure 2). The direction of maximum wear, as measured in degrees from the cup pole, ranged from 8.32 to 73.86 degrees. Differences in wear rates as a function of crosslinking dose, as well as presence/absence of a lip can be identified. Discussion. This wear measurement study of retrievals is the first application of a novel CMM technique to locate and quantify wear in HXL liners compared to conventional polyethylene controls. The study confirms the expectations of a tenfold reduction in wear rates that were based on in vitro testing [2]. The results are consistent with those of radiographic studies that have documented lower wear of HXL polyethylene in the hip compared to conventional polyethylene [3]. However, the current technique offers higher precision and reliability, and eliminates the large proportion of negative wear measurements common amongst radiographic methods. A sufficient number of liners have been measured to begin to differentiate wear between different radiation doses

INTRODUCTION. Deformation of modular acetabular press-fit shells is a topic of much interest for surgeons and manufacturer. Such modular components utilise a titanium shell with a liner manufactured from metal, polyethylene or ceramic. Initial fixation is achieved through a press-fit between shell and acetabulum with the shell mechanically deforming upon insertion. Shell deformation may disrupt the assembly process of inserting the bearing liner into the acetabular shell for modular systems. This may adversely affect the integrity and durability of the components and the tribology of the bearing. OBJECTIVE. Most clinically relevant data to quantify and understand such shell deformation can be achieved by cadaver measurements. ATOS Triple Scan III was identified as a measurement system with the potential to perform those measurements. The study aim was to validate an ATOS Triple Scan III optical measurement system against a co-ordinate measuring machine (CMM) using in-vitro testing and to check capability/ repeatability under cadaver lab conditions. METHODS. Two sizes of custom-made acetabular shells were deformed using a uniaxial/ two-point loading frame and measured repeatedly at different loads. Roundness measurements were performed using both the ATOS Triple Scan III optical system and a co-ordinate measuring machine and then compared. The repeatability was also tested by measuring shells pre and post insertion in a cadaver lab multiple times. RESULTS. The in-vitro comparison with CMM demonstrated a maximum difference of 5 µm at the rim and 9 µm at the measurement point closest to the pole of the shell. Deviation between the two systems increased towards the pole for the in-vitro measurements. However as press fit shells are designed to be loaded at the rim, this is likely where the maximum deflection will occur as a result of the highest force. Therefore, the increased difference between the systems towards the pole is of less importance compared with accuracy at the rim. Maximum repeatability was below 1 µm for the CMM and 3 µm for the ATOS Triple Scan III optical system. Repeatability of the ATOS Triple Scan III optical system was comparable between pre insertion (below 2 µm) and post insertion (below 3 µm) measurements in the cadaver lab. In addition these values were comparable to the repeatability measured during the in-vitro validation study (below 3 µm). This proves high repeatability not only for in-vitro conditions, but also for the cadaver lab as well. CONCLUSIONS. This study supports the view that the ATOS Triple Scan III optical system fulfils the necessary requirements to accurately measure shell deformation in cadavers. As a result, the authors propose further studies using cadavers to identify the impact of other factors upon shell deformation. Other factors to be measured include bone strength, shell diameter, under reaming and wall thickness

Introduction. Metal-on-polyethylene (MoP) is the most commonly used bearing couple in total hip replacements (THRs). Retrieval studies (Cooper et al, 2012, JBJS, Lindgren et al, 2011, JBJS) report adverse reactions to metal debris (ARMD) due to debris produced from the taper-trunnion junction of the modular MoP THRs. A recent retrospective observational study (Matharu et al, 2016, BMC Musc Dis) showed that the risk of ARMD revision surgery is increasing in MoP THRs. To the authors' best knowledge, no hip simulator tests have investigated material loss from the taper-trunnion junction of contemporary MoP THRs. Methods. A 6-station anatomical hip joint simulator was used to investigate material loss at the articulating and taper-trunnion surfaces of 32mm diameter metal-on-cross-linked polyethylene (MoXLPE) joints for 5 million cycles (Mc) with a sixth joint serving as a dynamically loaded soak control. Commercially available cobalt-chromium-molybdenum (CoCrMo) femoral heads articulating against XLPE acetabular liners (7.5Mrad) were used with a diluted new-born-calf-serum lubricant. Each CoCrMo femoral head was mounted on a 12/14 titanium alloy trunnion. The test was stopped every 0.5Mc, components were cleaned and gravimetric measurements performed following ISO 14242-2 and the lubricant was changed. Weight loss (mg) obtained from gravimetric measurements was converted into volume loss (mm. 3. ) and wear rates were calculated from the slopes of the linear regression lines in the volumetric loss versus number of cycles plot for heads, liners and trunnions. Additionally, volumetric measurements of the head tapers were obtained using a coordinate measuring machine (CMM) post-test. The surface roughness (Sa) of all heads and liners was measured pre and post-test. At the end of the test, the femoral heads were cut and the roughness of the worn and unworn area was measured. Statistical analysis was performed using a paired-t-test (for roughness measurements) and an independent sample t-test (for wear rates). Results and Discussion. The mean volumetric wear rates for CoCrMo heads, XLPE liners and titanium trunnions were 0.019, 2.74 and 0.013 mm. 3. /Mc respectively. There was a statistically significant decrease (p<0.001) in the Sa of the liners post-test. This is in contrast to the femoral heads roughness in which no change was observed (p = 0.338). This head roughness result matches with a previous MoP in vitro test (Saikko, 2005, IMechE-H). The Sa of the head tapers on the worn area showed a statistically significant increase (p<0.001) compared with unworn, with an associated removal of the original machining marks. The mean volumetric wear rate of the head tapers obtained using the CMM (0.028 ± 0.016 mm. 3. /Mc) was not statistically different (p=0.435) to the mean volumetric wear rate obtained gravimetrically (0.019 ± 0.020 mm. 3. /Mc) for the femoral heads. Therefore, wear of the heads arose mainly from the internal taper. The mean wear rates of the CoCrMo taper and titanium trunnion are in agreement with a MoP explant study (Kocagoz et al, 2016, CORR). Conclusion. This is the first long-term hip simulator study to report wear generated from the taper-trunnion junction of MoP hips

Expectations for ceramic-on-metal (COM) bearings included (i) optimal lubrication due to smoother ceramic heads (ii), reduction of metal ions due to elimination of CoCr heads, and (iii) ‘differential hardness’ reducing adhesive wear and squeaking (Firkins 2001, Williams 2007). Additional benefits included (iv) use of heads larger than for ceramic-on-ceramic (COC), (v) reduction in taper corrosion and (vi) simulator studies clearly demonstrated metal ions and wear both reduced compared to MOM (Firkins 2001, Williams 2007, Ishida 2007). However, contemporary ‘3rd body wear’ paradigms focused only on metal debris size range 0.025–0.035um (Firkins 2001). Thus, neglected was the effect of hip impingement, provoking release of large metal particles sized 20–200um (Clarke 2013). In this study, we compared COM retrievals using hypotheses that adverse COM cases would demonstrate a combination of (a) steeply inclined cups, (b) liner “edge-loading”, (c) Ti6Al4V contamination on ceramic, and (d) evidence of 3rd-body CoCr wear by large particles. As a case example, this 51-year old female had her metal-polyethylene (MPE) bearing revised to COM in June 2011. She reported no symptoms 1-year post-op, but scans revealed a palpable mass in the inguinal region of left hip. By March 2013 the patient reported mild pain in her hip, which progressed to severe by April 2014. Scans showed a solid and cystic iliopsoas bursitis while cup position had changed from 43o to 73o inclination. Revision was performed in June 2014, her joint tissues were found extensively stained due to metal contamination, and histology described formation of a large pseudotumor. Analysis of retrieved components was by interferometry, SEM and EDS. Detailed maps were made of wear areas in heads and cups and volumetric wear was determined by CMM techniques. This adverse COM example revealed large diametral mismatch (595um) compared to COM controls (75–115um). The ceramic head had a broad polar stripe of CoCr contamination, roughness 0.1–0.3um high. Equatorial ceramic areas showed arrays of thin metal smears that demonstrated elemental Ti and Al. The CoCr liner revealed wear area into cup rim, as “edge loading”, and also featured a focal rim-defect over 18o circumferential arc. Liner scratches were 20um wide and larger, and wear-rate of CoCr liner averaged approximately 50mm3 per year. In contrast, ceramic head had minimal wear. Our study highlights the underappreciated risk of impingement by metallic prosthetic components. Prior studies of ceramic heads showed black metallic smears. With COM we can anticipate that the broad polar smear will be CoCr alloy (wear of liner on head). However, Ti6Al4V smearing on ceramic heads is a notable signpost indicating impingement by the Ti6Al4V acetabular shell. The femoral neck (Ti6Al4V: CoCr), may also be damaged. Release of large metal particles, 1500-times larger than prior predictions, provoke a particularly adverse ‘3rd body wear’ (Halim, 2015). Such cases confirm our four hypotheses, that COM bearings will then fail in a way similar to MOM. In contrast, COC bearings are immune to such impingement and 3rd-body metal damage

Introduction. Retrieved metal-on-metal acetabular components are invaluable resources from which to investigate the wear behaviour of failed hip implants. New forensic and investigative techniques continue to be developed to help the surgeon further understand factors which contribute to early failure. We have developed a novel technique to locate the in vivo location of the primary wear scar of an explanted cup. Patients/Materials & Methods. Thirteen (13) patients with failed metal hip resurfacings were recruited and their acetabular components retrieved. A 3D wear map was generated and the precise location of the primary wear scar in each cup was identified using a coordinate measuring machine (CMM). This wear scar position and location was noted in relation to standard landmarks on the acetabular cup. All patients underwent a computerised tomography (CT) scan prior to revision surgery. The 3D positional map from the CMM was then co-registered with the implant on the patient's pelvic 3D CT scan. Results. A schematic diagram was generated revealing the 3D orientation and location in the patient of the acetabular primary wear scars for all 13 subjects. The distribution of the location of the in vivo primary wear scars was variable and unique for each of the patient's acetabular cup. Discussion. We were able to identify the location of the in vivo primary wear scar of all thirteen acetabular cups successfully with this novel method. This technique can only be recruited for acetabular components that have clearly identifiable features which can be identified on CT. This is the first study to co-relate the point of highest wear on the acetabular cup to its pre-failure position in vivo. Conclusion. This technique has made it possible to better understand the three-dimensional properties of wear behaviour and can be used in further studies to investigate variables that determine the orientation and position of the primary wear scar

The use of fourth generation ceramic as an orthopaedic biomaterial has proved to be a very efficient and has gained popularity for primary hip surgery in the last 8–10 years. Cumulative percentage probability of revision after 7 years for un-cemented CoC is 3.09% and for hybrid CoC is 2.00%, this compares favourably with traditional metal-on-UHMWPE un-cemented at 3.05% and hybrid at 2.35% (12th Annual Report - NJR, 2015). Such ceramic-on-ceramic hip prostheses are being implanted in ever younger, more active patients, and yet very few long-term large cohort retrieval studies are yet to be carried out due to the survivorship of the implants. It has been seen in previous studies that levels of wear in ceramic-on-ceramic bearing surface can be of the order of 0.2 mm. 3. /million cycles (Al-Hajjar, Fisher, Tipper, Williams, & Jennings, 2013). This is incredibly low when compared to studies that characterize wear in other bearing surface combinations. It has also been reported that an unusual stripe pattern of wear can occur in some in-vivo retrieved cups (Macdonald & Bankes, 2014) and it has further been postulated that this is caused by cup edge loading (Walter, Insley, Walter, & Tuke, 2004). The combined measurement challenge of stripe wear occurring at the edge of a low-wear ceramic-on-ceramic device is considerable, a solution to which is presented here. Current literature on wear measurement of such cases has been confined to in-vitro simulator studies and use of gravimetric measurement which by definition has limitations due to the lack of spacial characterisation. This paper details a novel method for measuring edge-wear in CoC acetabular liners. The method has been employed in an in-vitro study where it has been benchmarked against gravimetric measurements. These liners were measured on a CMM to determine the volume of material loss. The measurements were conducted as a blinded post-wear study akin to measurement of retrieved components. The most challenging part of this novel method was to create a reference geometry that replicates the free form edge surface of the ‘unworn’ cup using the residual post-wear surface. This was especially challenging due to the uncontrolled geometry at the cup edge and intersection of geometric features at this point. To achieve this, the geometry surrounding the wear patch was used to create a localized reference feature that minimised the effect of global form errors caused by hand polishing in the edge area. Furthermore, the reference geometry is compared with the measured surface to determine the linear penetration and volumetric wear loss. Result of this novel method can be seen in Fig 1. The findings have been compared to gravimetric results and a bar graph comparing two results can be seen in Fig 2. Overall the accuracy of the method for this cohort was 0.03–0.2 mm. 3. when compared to gravimetric reference measurements. This compares very favourably with previously published wear measurement methods and gives confidence in the ability to measure such small measurement volumes over complex geometry

Aims

This study investigates head-neck taper corrosion with varying head size in a novel hip simulator instrumented to measure corrosion related electrical activity under torsional loads.

Introduction. There is much current debate concerning wear and corrosion at the taper junctions of large head total hip replacements, particularly metal-on-metal hips. Is such damage a modern concern or has it always occurred in total hip replacement but not previously noted. To investigate this five explanted V40 Exeter femoral stems (Stryker Howmedica) were obtained following revision surgery at a single centre. In all cases, the 24–26 mm femoral heads were still attached. Hypothesis. In conventional ‘small head’ modular hip prostheses such as the Exeter, negligible wear and corrosion is seen at the taper junction of explanted devices. Methods. The articulating surface and the taper junction of each femoral heads was measured using a Mitutoyo LEGEX322 co-ordinate measuring machine (CMM) In each case a wear map was generated and the wear volume from the contact surface was calculated using a bespoke MATLAB program. The accuracy of such measurements has been previously shown to be within 0.5mm3. Results. Wear analysis of the articulating surfaces found unworn surfaces with each femoral head having less than 1 mm. 3. volumetric wear. All tapers had minimal wear with volumetric wear of less than 0.5 mm. 3. . Discussion and Conclusion. The wear volumes measured fall within the CMM measuring accuracy of 0.5mm. 3. Furthermore all tapers showed low wear volumes indicating that the taper junction had functioned correctly and distributed the load across the length of the truneon. Significance. This work adds to the growing evidence that taper problems in modern hip prostheses are associated with increasing head diameter and smaller taper dimensions

The poor outcome of large head metal on metal total hip replacements (LHMOMTHR) in the absence of abnormal articulating surface wear has focussed attention on the trunnion / taper interface. The RedLux ultra-precision 3D form profiler provides a novel indirect optical method to detect small changes in form and surface finish of the head taper as well as quantitative assessment of wear volume. This study aimed to assess and compare qualitatively tapers from small and large diameter MOMTHR's. Tapers from 3 retrieval groups were analysed. Group 1: 28mm CoCr heads from MOMTHRs (n=5); Group 2: Large diameter CoCr heads from LHMOMTHRs (n=5); Gp 3 (control): 28mm heads from metal on polyethylene (MOP) THRs; n=3). Clinical data on the retrievals was collated. RedLux profiling of tapers produced a taper angle and 3D surface maps. The taper angles were compared to those obtained using CMM measurements. There was no difference between groups in mean 12/14 taper angles or bearing surface volumetric and linear wear. Only LHMOMs showed transfer of pattern from stem trunnion to head taper, with clear demarcation of contact and damaged areas.3D surface mapping demonstrated wear patterns compatible with motion or deformations between taper and trunnion in the LHMOM group. These appearances were not seen in tapers from small diameter MOM and MOP THRs. Differences in appearance of the taper surface between poorly functioning LHMOMTHRs and well functioning MOP or MOM small diameter devices highlight an area of concern and potential contributor to the mode of early failure

Metal-on-metal retrieval studies indicated that MOM wear-rates could rise as high as 60–70mm3/year in short-term failures (Morlock, 2008). In contrast, some MOM and ceramic-on-ceramic (COC) devices of 1970's era performed admirably over 2–3 decades (Schmalzreid, 1996; Shishido, 2003). While technology has aided analysis of short-term MOM and COC failures (Morlock 2008; Lord 2011), information on successful THA remains scant. Lack of long-term data creates difficulties in setting benchmarks for simulator studies and establishing guidelines for use in standards. In this study we compared clinical and wear histories for a 30-year MOM and a 32-year COC to establish such long-term, wear-rates. The McKeeTM retrieval was cemented and made 100% of CoCr alloy (Fig. 1a). This patient had a right femoral fracture at 47 years of age, treated by internal-fixation, which failed. Her revision with a Judet implant also failed, leaving her right hip as a Girdlestone. At the age of 68, she had a McKee THA implanted in left hip, and used it until almost 98 years of age (Campbell, 2003). The COC case was a press-fit AutophorTM THA, head and cup made of alumina ceramic, with the only metal being the CoCr stem (Fig. 1c). This was implanted in a female patient 17-years of age active in sports (water-skiing). This modular THA was revised 32-years later due to hip pain from cup migration. Wear on these implants was identified by stereomicroscopy and stained red for photography (Fig. 1). Cup-to-neck impingement was denoted by circumferential neck notching, roughness was assessed by interferometry, and wear determined by CMM (Lord, 2011). McKee head wear covered 1092mm2 area (Figs. 1a, 2: hemi-area ratio 58%). There was no stripe wear and head roughness was 36nm (Ra). Cup wear covered an area of 1790mm2 (hemi-area 63%). Circumferential damage was noted on the supero-posterior femoral neck with scuff marks also on posterior collar (Fig. 2c). Head and cup wear amounted to 37.7 and 25.2mm3, respectively. Total MOM wear was 62.9mm3, indicating a wear-rate of 2.1mm3/year. Ceramic head wear consisted of two circular patterns (Fig. 1c), the major one of area 1790mm2 (hemi-area 79%). No wear stripes were identified. Non-worn and extensively worn surfaces had roughness (Ra) 17nm and 123nm, respectively. The cup showed 360o circumferential arc of rim wear with a small, non-wear zone inferiorly (Fig. 1c). Gray metallic transfer was evident, EDS revealing Co and Cr (Fig. 3a). Head and cup wear volumes were 77.2 and 54mm3, respectively. Total COC wear amounted to 131.2mm3 indicating a wear-rate of 4.1mm3/year. These two THA functioned successfully over 3 decades. The McKee retrieval had minor signs of impingement but no adverse “stripe wear”. This MOM performed satisfactorily due to good positioning and patient's advanced age (68 to 98Yrs of age). The COC patient was 17 years of age at index surgery and active. The ceramic cup showed 360o of edge wear, CoCr transfer and a COC wear-rate double that of the MOM retrieval. Thus the high ceramic wear-resistance protected this youthful patient

A 35-year-old female (age 35Yrs) had primary MOM total hip arthroplasty (THA) in 2008. At 8 months this patient postoperatively developed headaches, memory loss, vertigo, and aura-like symptoms that progressed to seizures. At 18 months review, she complained of progressive hip pain, a popping sensation and crepitus with joint motion. This patient weighed 284lbs with BMI of 38.5. Radiographs revealed the cup had 55° inclination, 39° anteversion (Fig. 1). Metal ion concentrations were high (blood: Co=126 mcg/L, Cr= 64mcg/L). Revision was performed in November 2010 A dark, serous fluid was observed, along with synovitis. The implants were well fixed and the femoral head could not be removed; thus the stem was removed by femoral osteotomy. With the head fused on this femoral stem, for the 1. st. time it was possible to precisely determine the habitual patterns of MOM wear relative to her in-vivo function. We investigated (1) size and location of wear patterns and (2) signs of cup-stem impingement to help explain her symptoms developed over 32 months follow-up. The retrieved MOM was a Magnum™ with head diameter 50mm and 50×56mm cup (Biomet). This was mounted on a Taperloc™ lateralized porous-coated stem. Components were examined visually and wear damage mapped by stereo-microscopy, interferometry, CMM, SEM, and EDS. Main-wear zone (MWZ) areas were calculated using standard spherical equations. 1. and centroidal vectors determined. The head-cup mismatch was 427um with the cup revealing a form factor of 228um. The cup showed wear area of 1275mm² that extended up to the cup rim over 150°arc. The cup rim was worn thin over a 90° arc with loss of cup bevel. The head showed an elliptical wear area of 2200mm. 2. located centrally on the superior-medial surface (ellipsoidal ratio ×1.2). Compared to the hemispherical surface (50mm: hemi-area = 3927mm. 2. ), the worn area represented hemi-area ratio of 56%. The centroidal vectors measured 8° anterior and 24° superior to the head's polar axis (Fig. 2). Stripe wear damage revealed multiple impingement sites. SEM and EDS revealed stripes were contaminated by metal transfer from the stainless-steel instruments used at revision. The main impingement position was identified (Fig. 3) indicating the site of repetitive subluxations whereby the subluxing head thinned the cup, i.e. “edge wear”. Cup and head wear patterns corresponded well, reinforcing our definition of the MWZ locations in vivo. The femoral MWZ was centrally located superiorly and medially with respect to the polar axis of the femoral neck and head. The noted impingement position indicated this patient had experienced repetitive subclinical subluxations (RSS). 2. The taper inside the fused head may also have been a contributory factor that we cannot ignore. Nevertheless her excessive cup thinning was likely a result of a steep cup and considerable anteversion allowing the femoral head to sublux over the cup rim, thus thinning the cup and wearing the rim bevel, and producing MOM wear debris

The poor outcome of large head metal on metal total hip replacements (LHMOMTHR) in the absence of abnormal wear at the articulating surfaces has focussed attention on the trunnion/taper interface. The RedLux ultra-precision 3D form profiler provides a novel indirect optical method to detect small changes in form and surface finish of the head taper as well as a quantitative assessment of wear volume. This study aimed to assess and compare qualitatively the tapers from small diameter with LHMOMTHR's. 3 groups of retrieval tapers were analysed (Group 1: 28mm CoCr heads from MOMTHRs (n=5); Group 2: Large diameter CoCr heads from LHMOMTHRs (n=5); Group 3: 28mm heads from metal on polyethylene (MOP) THRs; n=3). Clinical data on the retrievals was collated. Both bearing surfaces and head tapers were measured for wear using the Redlux profiling non contact measurement system. Measurements included taper angle and 3D surface maps. Taper angles obtained with the Redlux method were compared to those obtained using CMM measurement on 3 parts. The Redlux profiling, including imprints, was also repeated 3 times to gauge potential errors. There was no difference in mean 12/14 taper angles between groups. There was no difference in volumetric and linear wear at the bearing surface between groups. Only the LHMOMs showed transfer of pattern from the stem to the internal head taper, with clear demarcation of the contact and damaged area between head taper and stem trunnion. 3D surface mapping demonstrated wear patterns compatible with motion or deformations between taper and trunnion in the LHMOM group alone. Discussion: Differences in appearance of the taper surface between LHMOMTHRs and MOP or MOM small diameter devices highlight an area of concern and potential contributor to the mode of early failure. Further work is required to fully qualify the Redlux method capabilities

Introduction The ABG I acetabular insert is an ultra high molecular weight polyethylene (UHMWPE) component used in primary hip arthroplasty. Studies have shown early osteolysis and aseptic loosening of the ABG I uncemented cup compared with other implants. Theories advocate that loosening is initiated by the biological response to insert wear debris; wear volume and the distribution of particle size are considered to be important parameters. This study analysed explanted plastic inserts to identify any mechanical properties that may have contributed to early failure. Materials and Methods 21 ABG I acetabular components were revised due to aseptic loosening over a 16 month period. Silicone casts of the insert sockets were made and volumetric analysis performed using a shadowgraphing technique and a coordinate measuring machine (CMM). The UHMWPE inserts were divided into uniform pieces with a diamond-tipped microsaw and analysed for hardness, wear, stress and strain properties using a microhardness tool, pin-on-plate analysis and small punch testing. We performed identical tests on explanted inserts from other manufacturers. Results We present the findings of the above tests and provide suggestions as to why these particular implants are more prone to early failure when compared with other common implants. We also discuss the results of volumetric analysis by shadowgraphing compared with CMM

Aims: To solve the major problems of osteolysis due to particle debris in total hip arthroplasty, highly cross-linked UHMWPE were developed. Investigations on early retrieved components of Durasul™ (Centerpulse Orthopedics Ltd.) provide the opportunity to evaluate the highly crosslinked components for wear damage or other effects on the material. Methods: 12 Durasul™ alpha cups were surgically retrieved and analyzed. The range of in-vivo duration of the cups was between 3 and 15 months. The reasons for revision were not related to material failure. The investigations were made by microscopy and CMM measurement. To differentiate between creep and wear, the memory effect was used. Results: In the articulation, machining marks look partly flattened, or show a highly scratched surface. The loaded area shows some microscopic changes of the morphology like ripples and folds, which are shear-induced ripple formations and material overlappings. In some cases the retrieved cups show a yellow discoloration, indicating the in-vivo absorption of synovial liquid proteins. Conclusion: The findings from the retrievals showed that there is no adverse wear at 3–15 months and there were no material failures due to wear, delamination or cracks. All the effects are accumulating on the articulating surface and lead to the dull scratched morphology. Mechanisms like material overlapping and yellowing are reported also from conventional UHMWPE and do not show adverse effects on the long-term behaviour of the material