Using a femoral head from one manufacturer on the stem of another manufacturer poses the risk that the taper interface between the components do not contact correctly and the performance of the joint will be impaired. The cohorts in this study are a combination of modular Birmingham Hip Resurfacing (BHR) and Adept femoral heads on CPT stems. The study reviews the geometry of the taper interfaces to establish if the taper clearance angles was outside of the normal range for other taper interfaces. In addition the rates of material loss from the bearings and taper and a ranking of the stem damage were reviewed to determine if the levels of loss were above that seen for other similar joints. The material loss analysis demonstrated that the rates or levels of loss from the bearings, taper and stem are no different to levels published for manufacturer matched joints and in many cases are lower. The results demonstrate that the taper clearance angles for the mixed manufacturer joints (BHR-CPT: 0.067 to −0.116, Adept-CPT: 0.101 to −0.056) were within the range of other studies and manufacturer matched clearances (0.134 to −0.149). Using components from different manufacturers has not in this instance increased the level of material loss from the joints, when compared to other similar manufacturer matched joints.
Introduction. As the population continues to grow and age, the incidence of revision total knee replacement (RTKR) is expected to rise significantly. Modularity within revision total knee systems is common, and recognition of modular junctions as an important source adverse local tissue reaction (ALTR) has not yet been fully described in the literature. In both hips and knees, ALTR may be caused by wear debris from articulating surfaces, stress shielding, and other classic areas of focus, but now attention is shifting towards the role of corrosion products from modular junctions. In severe cases, junctions can become welded together creating significant hurdles in revisions and potentially altered biomechanics in vivo. In view of these issues, the present study was undertaken: (i) to examine the level of damage observed in modular junctions of total knee prostheses obtained at revision, (ii) to correlate the severity of surface damage to the design and composition of the mating components, and (iii) to associate patient demographics and comorbidities with the spectrum of corrosion and fretting seen in retrieved implants. Methods. 117 TKR components from 76 patients were examined after retrieval from revision procedures performed at a single institution. Patient demographics and clinical data were compiled. The retrievals consisted of 57 femoral components and 60 tibial components from a diverse range of manufacturers. The implants were disassembled manually, or in a mechanical testing machine if cold welded, and separated into groups based on mating material type. Modular junctions were then examined using stereomicroscopy (Wild) at magnifications of X6 to X31. Upon inspection, damage on the male component was graded using modified Goldberg scales for corrosion and fretting (Table 1). Factors associated with trunnions having damage scores of 3 or higher were evaluated using standard statistical procedures to determine the susceptibility for corrosion of each junction type and location. Results. Approximately two-thirds (64%) of trunnions had corrosion scores of 3 or higher. As seen in chart 1, junctions containing titanium alloys were the most susceptible to corrosion with the femoral component being the most prevalent. The most severe cases of corrosion (score of 5) were seen in
