Introduction. Modular junctions in total hip replacement (THR) have been a primary source of fretting and corrosion which can lead to implant failure. Fretting is a result of unintended micromotion between the femoral head and stem tapers and is suspected to result after improper taper seating during assembly. Two design factors known to influence in-vitro taper assembly mechanics are relative taper alignment—mismatch angle—and the surface finish—micro-grooves. However, these factors have not been systematically evaluated together. Objective. The objective of this study was to employ a novel, micro-grooved finite element (FEA) model of the hip taper interface and assess the role of taper mismatch angle and taper surface finish—smooth and rough—on the modular junction mechanics during assembly. Methods. A two-dimensional, axisymmetric model of a CoCrMo femoral head taper and Ti6Al4V stem taper was created using median measurements taken from over 100 retrieved implants. Micro-grooves on the stem and head taper were modeled using a sinusoidal function with amplitude and period corresponding to median retrieval measurements. To evaluate effects of a “smooth” head taper surface finish, additional models were run with a head taper having a flat edge (no micro-grooves). Lastly, mismatch between the stem and head taper was varied between distal-locked, no mismatch, and proximal-locked. To simulate assembly during surgery, boundary conditions were applied to move the femoral head taper at a constant velocity onto the stem taper until a 4kN reaction load was achieved. Models were assembled and meshed in ABAQUS Standard (v 6.17) using four-node linear hexahedral, reduced integration elements. Contact was modeled between the stem and head taper using surface-to-surface formulation with penalty contact and a coefficient of friction of 0.2. Forty simulations (5 mismatch angles x 2 head taper surface types x 4 stem taper surface finishes) were run. Outcome variables included contact area, contact pressure, equivalent plastic strain, and number of micro-grooves undergoing plasticity. Results. As expected, taper mismatch angle drove the location of contact to the distal or proximal ends. Increasing taper mismatch led to significant decreases in contact area for both micro-grooved and flat head taper models (Figure 1A). Taper mismatch had minimal effects on contact pressure (∼2.15 GPa) with the “rough” head taper surface finish but influenced the range of contact pressures (1.30 – 1.91 GPa) in the “smooth” head taper models (Figure 1B). Stress at the micro-grooves varied depending on the stem taper surface finish (Figure 2). Significant plastic deformation of the micro-grooves was only found in models with the “rough” head taper surface finish. Conclusion. Regardless of the taper surface finish, contact area decreased by 30% – 58% when going from a 3’ – 12’ mismatch. Reduced contact area may significantly influence the long-term stability of the implant. Modeling the taper micro-grooves led to plastic deformation consistent with those found from retrieved implants—indicating the importance of modeling the surface finish of tapers. These models will be used to identify the optimal design factors to maximize stability of the modular taper junctions. For any figures or tables, please contact authors directly

Recent NICE guidance recommends use of a well proven cemented femoral stem for hip hemiarthroplasty in management of fractured neck of femur. The Exeter Trauma Stem (ETS) has been designed based on the well proven Exeter hip stem. It has a double taper polished stem design, proclaimed to share geometry and surface finish with the Exeter hip. This study investigated the surface finish of the two stems in order to investigate the hypothesis that they were different. Two ETS and two Exeter stems were examined using a profilometer with a sensitivity of one nanometer. Macroscopic visual inspection showed that the two Exeter stems had significantly smoother surface finish than the ETS stems. The roughness average (RA) values on the ETS stems were approximately an order of magnitude higher than those of the Exeter stems, mean of 0.235μm compared with 0.025μm (p<0.0001). This difference in surface finish has implications for the biomechanical functioning of the stem. Previous change of the Exeter stem to a matt surface-finish in 1976 resulted in a significant increase in stem failure rates and an understanding of the importance of the polished surface-finish in order to function within a taper-slip philosophy. By changing the surface finish in the ETS stem, longevity of the implant may similarly be affected. Clinical results have yet to be published demonstrating this. We recommend the manufacturer reconsiders the surface finish of the ETS stem to ensure it functions as well as the Exeter primary stem with which it shares a design philosophy

Introduction: The purpose of this study was to report on the minimal 10-year followup results of a prospective randomized and a historical series of low friction cemented hip arthroplasties according to the surface finish of the femoral implant. Patients and Methods: The prospective randomized series included 284 patients (310 hips) with a mean age of 64.1 years. Among these 310 hips, the femoral component had a highly polished surface (Ra = 0.04 micron, MKIII, Stryker) in 165 hips, and a matte surface finish (Ra = 1.7 microns, CMK3, Vector Orthopedique) in the remaining 145 hips. The historical series that was operated by the sames surgeons according to the same surgical technique included 111 patients (123 hips) with a satin finish femoral component (Ra = 0.9 micron, CMK2, Sanortho). Clinical results were rated according to the Merle d’Aubigne hip score. Radiologic analysis was performed according to the criteria of Barrack et al. for the definition of loosening. Moreover, a survival analysis according to the actuarial method was conducted. Results: At the minimum 10-year follow-up evaluation, 43 patients (48 hips) were lost to follow-up (0.3 to 8.7 years), 80 patients (83 hips) were deceased (0.1 to 13.6 years), 26 patients had revision of either or both components (0.9 to 15.9 years), and 246 patients (276 hips) were alive and had not been revised after a mean 12.3 ± 1.9 years (10 to 16 years). Radiologic loosening of the femoral component, including revision, occured in one, four, and 15 hips for the polished, stain, and matte groups, respectively. The survival rate at 13 years of the femoral component, using loosening as the end point, was 97.3 ± 2.6% (95% CI, 92.2 to 100%), 97.1 ± 2.1% (95% CI, 93 to 100%), and 78.9 ± 5.8% (95% CI, 67.6 to 90.3%) for polished, satin, and matte stems, respectively. Discussion: This study demonstrated that cement fixation of a femoral component was more reliable in the long term with a polished or satin surface finish. Based upon our results and the review of the literature, we recommend abondoning the use of cemented stems with a surface roughness greater than 1 micron

Introduction. The release of metallic debris can promote many adverse tissue reactions, as metallosis, necrosis, pseudotumors and osteolysis . 1–3. This debris is mainly generated by the fretting-corrosion mechanism due to the geometric difference in the head-stem interface . 4. Retrieval and in silico analysis showed the roughness of the stem-head interface appears to play an important role in the volume of material lost and THA failure . 5–7. The technical standard ISO 7206-2 recommends the measurement of average roughness (Ra) and max height of the profile (Rz) to control the quality of the surface finish of articulating surfaces on THA implants. However, despite the importance of the trunnion roughness, there is no specific requirement for this variable on the referred technical standard. The present study carried out a surface finish analysis of the trunnion of hip stems from five distinct manufacturers. Methods. Four stems (n = 4) from five (5) distinct manufacturers (A, B, C, D, and E) were used to evaluate the roughness of the trunnion. All the stems are similar to the classical Exeter stem design, with a 12/14 taper and a polished body surface. The roughness of trunnions was evaluated according to ISO 4287 and ISO 13565-2. The total assessment length was 4.8 mm with 0.8 mm cut-off. The first and last 8.33% of assessment length were not considered. The measurements of all samples were made in a rugosimeter with 2 µm feeler ITP (Völklingen, Germany), the velocity of 0.5 mm.s. -1. , and a force of 1.5 mN. The calibration was made at 20 ºC and relative humidity at 50%. The Kruskal Wallis with post hoc Nemenyi test was used to evaluate the difference of Ra among the manufacturers. The confidence level was set at 5%. Results and Discussion. The analysis of surface finish revealed different roughness among the manufactures (p < 0.005), with Ra between 0.061 µm to 3.184 µm and Rz varying of 0.41 µm to 12.69 µm. The manufacturers A and E had a Ra (2.587±0.050 µm and 3.146±0.031µm) of the trunnion similar to founded by Panagiotidou et al (2013). Within such range, the trunnion has shown a high presence of pit . 8. The manufacturer C, on the other hand, had the best surface finish of the trunnion (Ra = 0.069±0.010 µm and Rz = 0.505 ± 0.076 µm). This more smooth surface might increase the taper strength, reduce the shear stress and the susceptibility to the fretting-corrosion damage . 4,8. . Conclusion. The results were worrying because there is great variability of roughness among the manufacturers with the occurrence of trunnions with roughness too high. Nevertheless, the ISO technical standard does not recommend any procedure or minimum parameters acceptable for the surface finish of the trunnion. The revision of ISO 7206-2 would guarantee better control of trunnion roughness to reduce the amount of metallic debris and increase the safety of THA implants. Additional research is needed to determine a target value for this variable. For any figures or tables, please contact authors directly

The role of surface finish on the survivorship of cemented stems is controversial. The purpose of this study is to prospectively evaluate the mid-term clinical and radiographic performance of a cohort of patients who underwent total hip replacement with two identical cemented femoral stems differing only in surface finish (VerSys, Zimmer, Warsaw, IN). 64 total hip replacements with a rough stem (Ra: 70–100 micro inches) and 138 total hip replacements with a satin finish stem (Ra: 20–25 micro inches) were followed clinically and radio graphically for 4 to 7 years. All surgeries were performed by one surgeon, during a period of 1 year, utilizing the same surgical approach and technique, ace tabular cup, cement type and cementing technique. The groups had similar demographics, diagnosis, preoperative clinical score, cement mantle quality, alignment, and length of follow up. The preoperative and postoperative Hospital for Special Surgery Hip Score at last follow up of the patients with a successful operation was not significantly different among the two groups. Five hips in the rough group and none in the satin group developed aseptic loosening and required revision (p=0.0009). The femoral bone-cement interface revealed progressive radiolucent lines or osteolysis in 8 out of 64 rough stems and in 3 out of 138 satin stems (p=0.01). There were progressive radiolucenciesor osteolysis in 44 out of possible 448 Gruen zones in the rough surface group and in 8 out of possible 966 Gruen zones in the satin finish group(p< 0.001). A rough, textured stem is more likely to fail at intermediate follow-up than a satin surface stem. We recommend that the surface of cemented stems should be satin or polished, with a Ra of less than 20 micro inches

Particulate debris has been demonstrated to have a major role in the aseptic loosening of artificial joints. Biological activity is stimulated by particles of size 0.1 to 10 microns with maximum affect being seen in particles of approximately 0.5 microns. This study investigated the particle size of wear debris produced at the stem/cement interface in cemented artificial hips comparing different materials and surface finishes of the stem. Materials and Methods: The stem surfaces of three cemented femoral prostheses with different surfaces were used as templates, one smooth (Exeter, How-medica), one slightly rough (Elite, DePuy) and one very rough (Capital, 3M). Three commonly used implant materials were compared, cobalt chrome, stainless steel and titanium alloy. Test plates were manufactured in each material and with each of the three surface finishes. The plates were opposed to cement pins in a sliding wear tester. The debris produced was collected, filtered and examined under an electron microscope. Representative samples of particles produced by each test series were measured and aspect ratios calculated. Plates were also measured pre and post test to ensure no significant change in surface roughness during testing. Results: Each of the materials demonstrated an increase in mean particle size with increasing roughness of the test surfaces. This was more marked for titanium alloy than for cobalt chrome. For any given surface roughness the size of particles produced was smallest for the hardest material (cobalt chrome) and largest for the softest material (titanium alloy). Conclusion: The majority of particles produced were within the biologically active range. Particle size of debris was related to surface roughness with rougher surfaces producing larger particles. Harder materials produced smaller particles than softer materials and more particles in the biologically active range

The role of surface finish on the survivorship of cemented stems is controversial. The purpose of this study is to prospectively evaluate the mid-term clinical and radiographic performance of a cohort of patients who underwent total hip replacement with two identical cemented femoral stems differing only in surface finish (VerSys, Zimmer, Warsaw, IN). 64 total hip replacements with a rough stem and 138 total hip replacements with a satin finish stem were followed clinically and radiographically for 4 to 7 years. All surgeries were performed by one surgeon. The groups had similar demographics, diagnosis, length of follow up, cement mantle quality and alignment. The preoperative and postoperative Hospital for Special Surgery Hip Score at last follow up was not significantly different among the two groups. Five hips in the rough group and none in the satin group developed aseptic loosening (p=0.0009). The femoral bone-cement interface revealed progressive radiolucent lines or osteolysis in 8 out of 64 rough stems and in 3 out of 138 satin stems (p=0.01). There were progressive radiolucencies or osteolysis in 44 out of possible 448 Gruen zones in the rough surface group and in 8 out of possible 966 Gruen zones in the satin finish group (p< 0.001). A rough, textured stem is more likely to fail at intermediate follow-up than a satin surface stem. We recommend that the surface of cemented stems should be satin or polished, with a Ra of less than 20 microinches

The role of surface finish on the survivorship of cemented stems is controversial. The purpose of this study is to prospectively evaluate the mid-term clinical and radiographic performance of a cohort of patients who underwent total hip replacement with two identical cemented femoral stems differing only in surface finish (VerSys, Zimmer, Warsaw, IN). 64 total hip replacements with a rough stem (Ra: 70–100 microinches) and 138 total hip replacements with a satin finish stem (Ra: 20–25 microinches) were followed clinically and radiographically for 4 to 7 years. All surgeries were performed by one surgeon during a period of 1 year, utilizing the same surgical technique, acetabular cup, cement type and cementing technique. The groups had similar demographics, diagnosis, preoperative clinical score, cement mantle quality, alignment, and length of follow up. The preoperative and postoperative Hospital for Special Surgery Hip Score at last follow up of the patients with a successful operation was not significantly different among the two groups. Five hips in the rough group and none in the satin group developed aseptic loosening (p=0.0009). The femoral bone-cement interface revealed progressive radiolucent lines or osteolysis in 8 out of 64 rough stems and in 3 out of 138 satin stems (p=0.01). There were progressive radiolucencies or oste-olysis in 44 out of possible 448 Gruen zones in the rough surface group and in 8 out of possible 966 Gruen zones in the satin finish group (p< 0.001). A rough, textured stem is more likely to fail at intermediate follow-up than a satin surface stem. We recommend that the surface of cemented stems should be satin or polished, with a Ra of less than 20 microinches

Bone-cement shrinkage has never been quantified in a stem/cement/femur construct. We observed gaps around femoral stems in transverse sections of stem/cement/femur constructs; a greater proportion of stem/cement (s/c) interface gaps were found around grit blasted sections of stems than satin finished sections. If s/c gap formation were a shrinkage artifact then mantles with few s/c interface gaps must manifest shrinkage elsewhere, at the c/b interface or voids. ‘Mould-gaps’ at a c/b interface have been described previously but not quantified. We analysed the area of gaps at both interfaces. We hypothesised 1) Total gap area was the same for all transverse sections. 2) Satin sections had greater c/b gap areas than grit sections. Transverse sections of stem/cement/femur constructs were processed to highlight gap areas. Five stems had a satin finish (Ra 0.75 um) and five were proximally grit-blasted (Ra 5.3 um). Sections were coated with matt black spray paint and then polished with emery paper. This process left all interface gaps and voids filled with black paint, which facilitated digital imaging. Gaps were visually identified and measured using Image-Pro. Gap areas for each transverse section were normalised by the area of cement in that section. Gaps were not evenly distributed; there was obvious localisation at both interfaces. No significant difference found between surface finishes in total gap area ((satin 3.1% ± 1.4):(grit 3.4% ± 1.5)), supporting our first hypothesis. S/c gap areas were significantly greater around grit blasted sections ((satin 0.1% ± 0.4):(grit 1.9% ± 1.7) p< 0.0001). C/b gap areas were significantly greater around satin finished sections ((satin 2.3% ± 1.3):(grit 1.0% ± 0.9) p< 0.0001), supporting our second hypothesis. Shrinkage can localise into large interface gaps; which must lead to stress concentrations. C/b gaps are potentially benign as they can fill with bone. Cement failure at points of s/c contact would generate debris hindering bone formation

In England and Wales in 2012 over 160,000 primary total hip and knee replacements were performed with 57% of hip replacements utilising uncemented prostheses. The main cause of failure, affecting approximately 10% of patients, is aseptic loosening. Previous research has found that functionalising titanium with lysophosphatidic acid (LPA) induces an increase in human osteoblast maturation on the implant surface through co-operation with active metabolites of vitamin D3. This feature, the small size of the LPS molecule and its affinity to readily bind to titanium and hydroxylapatite makes it an especially desirable molecule for bone biomaterials. Nevertheless biomaterials that also demonstrate anti-microbial properties are highly desirable.

To test the antimicrobial efficacy of the LPA-functionalised titanium, a clinical isolate of Staphylococcus aureus, obtained from an infected revision surgery, was cultured on the surface of titanium discs functionalised with 0, 0.1. 0.5, 1, 2 and 5μM LPA. Bacterial adhesion was quantified at 1, 2, 6, 12 and 24 hours by live/dead counts and biofilm mass quantified by crystal violet staining after 24, 48, 72 and 96 hours culture. To elucidate the mechanisms of action of LPA, proteomic analysis of adhered bacteria was performed using SDS-PAGE and Western blots.

500nM to 1μM LPA were the optimum concentrations to significantly inhibit bacterial adhesion (ANOVA, p<0.001). These concentrations also reduced biofilm mass on the surface of the titanium. Proteomic analysis highlighted an increase in low molecular weight proteins as a result of optimal LPA surface concentrations. Fatty acid chains as found in LPA have previously been associated with causing leakage of low molecular weight proteins through increased cell membrane permeability.

LPA coatings have the potential to enhance implant osseointegration whilst simultaneously reducing bacterial attachment. This technology may reduce both septic and aseptic failure of cementless joint prostheses, ultimately prolonging implant longevity and patient quality of life.

Aims. Periprosthetic hip fractures (PPFs) after total hip arthroplasty are difficult to treat. Therefore, it is important to identify modifiable risk factors such as stem selection to reduce the occurrence of PPFs. This study aimed to clarify differences in fracture torque, surface strain, and fracture type analysis between three different types of cemented stems. Methods. We conducted biomechanical testing of bone analogues using six cemented stems of three different types: collarless polished tapered (CPT) stem, Versys Advocate (Versys) stem, and Charnley-Marcel-Kerboull (CMK) stem. Experienced surgeons implanted each of these types of stems into six bone analogues, and the analogues were compressed and internally rotated until failure. Torque to fracture and fracture type were recorded. We also measured surface strain distribution using triaxial rosettes. Results. There was a significant difference in fracture torque between the three stem types (p = 0.036). Particularly, the median fracture torque for the CPT stem was significantly lower than that for the CMK stem (CPT vs CMK: 164.5 Nm vs 200.5 Nm; p = 0.046). The strain values for the CPT stem were higher than those for the other two stems at the most proximal site. The fracture pattern of the CPT and Versys stems was Vancouver type B, whereas that of the CMK stem was type C. Conclusion. Our study suggested that the cobalt-chromium alloy material, polished surface finish, acute-square proximal form, and the absence of a collar may be associated with lower fracture torque, which may be related to PPF. Cite this article: Bone Joint Res 2022;11(5):270–277

Historically we know that all femoral, cemented stems have not performed the same. The Muller stem with its sharp comers did not perform as well as the Charnley femoral component. Titanium femoral components have not performed as well in the cemented situation as have stiffer chrome cobalt components. Today we have come to recognise that the durability of a cemented femoral component is dependent on a number of variables to include stem geometry and surface finish as well as the cement technique. Since several designs including the Trapezoidal-28, the Exeter, and the Iowa have incorporated various surface finishes over time, the issue of surface finish is one that some investigators think is relatively important. Components with rougher surface finishes adhere better to cement, decrease cement strains, and when they become loose are more likely to abrade cement. Components with smooth surface finishes do not adhere to cement, place cement under compression and when they become loose they are less likely to abrade cement. When these three stems were evaluated with both smooth and matte finishes the smooth surface finish stems have always demonstrated better results with less loosening and less osteolysis. However some matte finish designs have performed well including the CAD and the HD-2. Whatever prosthesis is utilised all investigators agree that it is optimal to have the prosthesis surrounded by cement, hence the use of centralisers. Hence today all would agree that the surgeon should use a torsionally sound stem and place an adequate cement mantle around that stem at the time of surgery .If that can be achieved all stems may be equal, however if cement mantle defects are inevitable a smooth surface finish probably has better durability

The effects of wear particles on artificial hip joints are well documented. Aseptic loosening has been demonstrated to be dependent on both particle numbers and particle size. This study investigated the effects of stem material and surface finish on particles produced at the stem/cement interface in cemented artificial hips. Three commonly used implant materials of different hardness were investigated: cobalt chrome, the hardest of the three materials, stainless steel and titanium alloy which was the softest material tested. The surfaces of three femoral stems with different surface finishes were measured and used as templates; the Exeter which is highly polished, the Charnley which is moderately rough and the Capital which is very rough. Test plates were manufactured in each material and with each surface finish making 9 sets of plates in all. The plates were opposed to cement pins (CMW) in a sliding wear tester. The volume of debris produced was calculated from measurements of the pins pre- and post-test. The debris was collected, filtered and examined under the electron microscope, which allowed particle sizes of a representative sample of debris to be measured. From this mean particle size was calculated. Volume of debris: for all three materials the roughest surface produced the greatest volume of debris and the smoothest surface the least. For any given surface finish the softest material produced the greatest volume of debris and the hardest material the least. Size of particles: for all three materials the roughest surfaces produced the largest particles and the smoothest surface the smallest particles. For any given surface finish the hardest material produced the smallest particles and the softest material produced the largest particles

Introduction: To investigate the head/neck interface of total hip replacements and to see whether the use of small spigots (minispigots) results in enhanced wear and corrosion of tapers compared to standard spigots and the influence of the surface finish on this. Methods: In the total hip replacement combinations the heads were made of cobalt-chrome (CoCr) and the stems of titanium alloy (Ti). Firstly wear and corrosion of minisigots were compared with standard spigots (Test 1) and secondly, these minispigots were compared with another minispigot with a smoother taper surface finish (Test 2). The samples were immersed in aerated Ringers solution (37°C) and loaded for 10 million cycles. The specimens surface parameters and profiles were measured before & after the test. Electrochemical static corrosion tests were carried out on the rough & smooth minispigots from Test 2 where the current was measured with constant potential under loaded and non-loaded conditions. A cyclical sinusoidal load of 1500-200 Newtons for 1000 cycles at ~1 Hz was used. Pitting tests measured the current while increasing and then decreasing the potential of non-loaded and loaded specimens. Two newly manufactured rough and smooth minispigots were subjected to the same electrochemical corrosion tests. Results: In Test 1 the results demonstrated that pre-test the surfaces of the female tapers were similar for all heads. Post-testing the Ra values on the female tapers had become greater for the minispigots compared with standard spigots. An abrupt change was noted on the surface profile of the female taper where it was in contact with the male Ti taper, indicating the the CoCr head had corroded. The Ti male tapers were unchanged. Scanning electron microscopy showed that the coarser profile in the corroded region of the CoCr was similar to the profile on the Ti male taper. Pitting corrosion was evident in the grooves on the CoCr. In Test 2 the smooth spigots were not affected, but in the rough minispigots, Ra values had increased in the female tapers. Static corrosion tests showed evidence of fretting in the rough but not the smooth minispigots. When comparing new rough & smooth minispigots, static corrosion testing with clyclical loading showed that for minispigots with a rough finish the current fluctuated with each cycle. Pitting scans showed a greater hysteresis with the rough minispigot compared with the smooth minispigot indicating potentially greater corrosion in the former. Conclusion: The cobalt-chrome/titanium alloy combinations where the surface finish on the male taper was coarse, corrosion was increased in minispigots compared with standard spigots. This was due to the smaller area of contact of the minispigot at the interface. This corrosion appears to be mediated through the mechanism of fretting corrosion. Surface finish was crucial and corrosion of the minispigot was reduced if the surface finish was smooth. Manufacturers should investigate the effect of surface finish on the corrosion of their tapers particularly where cobalt-chrome/titanium alloy combinations are used

Aims: To investigate whether the use of mini-spigots result in enhanced wear and corrosion of tapers compared to standard spigots and the influence of the surface finish on this. Methods: The heads were cobalt chrome and the stems titanium alloy. Firstly wear and corrosion of standard spigots were compared with mini-spigots and secondly, these mini-spigots with another mini-spigot with a smoother surface finish. The samples were immersed in aerated Ringers solution (37°C) and loaded for 10 million cycles. Then samples were sectioned and the surface parameters measured and interfaces investigated using scanning electron microscopy. Static corrosion tests were used under loaded and non-loaded conditions and pitting tests for non-loaded samples. Results: Pre-experimentation the surfaces of the female tapers were similar for all heads. At the end of the first test the surface parameters on the female tapers had become significantly greater (p=0.034) for the mini-spigots compared with standard spigots and an abrupt change noted on the surface profile of the female taper where it contacted the male taper, indicating that the cobalt chrome head had corroded. Scanning electron microscopy showed that the coarser profile in the corroded region of the cobalt chrome head was similar to the profile on the titanium stem taper. Pitting corrosion was evident in the grooves on the cobalt chrome. The smooth mini-spigots were less affected. Conclusions: In cobalt chrome- titanium alloy combinations where the surface finish on the taper is coarse, corrosion is increased on a mini spigot compared with standard spigot. Surface finish is crucial and corrosion of the mini spigot is reduced if the surface finish is smooth

Introduction. The National Joint Registry has recently identified failure of large head metal on metal hip replacements. This failure is associated with the high torque at the interface of standard modular taper junction leading to fretting and corrosion. A number of manufacturers produce mini spigots, which in theory, provide a greater range of motion as the neck head junction is reduced. However, the relative torque to interface ratio at this junction is also increased. In this study we investigated hypothesis that the use of small spigots (minispigots) will increase wear and corrosion on modular tapers. Methods. Wear and corrosion of spigots were compared in-vitro when loaded with a force representative of the resultant force passing through the hip. The heads (female tapers) were made of cobalt-chrome-molybdenum (CoCrMo) and the stems (male tapers) of titanium alloy (Ti). Commercially available tapers and heads were used. The surface parameters & profiles were measured before & after testing. Electrochemical static and dynamic corrosion (pitting) tests were performed on minispigots under loaded and non-loaded conditions. Results. Post-testing the surface parameters Ra, Ry & Rz on the head taper associated with the minispigots had become greater compared with standard spigots. In all instances the profile of the titanium male tapers was unchanged. SEM showed the corroded region of the head was similar to the profile on the Ti male taper, with evidence of pitting in the cobalt chrome. In the CoCrMo/ Ti combinations, wear and corrosion were increased in minispigots compared with standard spigots. On minispigots the rough surface finishes were affected more severely than those with a smoother surface. Static corrosion tests showed evidence of fretting in the rough but not the smooth minispigots. Pitting scans showed a greater hysteresis with the rough surface finishes on the minispogot indicating potentially greater corrosion in the former. Conclusion. The relative size of the taper in comparison to the head combined with the surface finish was crucial. As the relative torque to interface ratio at this junction increased corrosion of the cobalt chrome head increases and is further enhanced if the surface finish on the tapers is rough

Introduction:. There has been widespread concern regarding the adverse tissue reactions after metal-on-metal (MoM) total hip replacements (THR). Concerns have also been expressed with mechanical wear from micromotion and fretting corrosion at the head/stem taper junction in total hip replacements. In order to understand the interface mechanism a study was undertaken in order to investigate the effect of surface finish and contact area associated with modular tapers in total hip replacements with a single combination of materials of modular tapers. Methods:. An inverted hip replacement setup was used (ASTM F1875-98). 28 mm 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 surface finish. Wear and corrosion of taper surfaces were compared after samples were sinusoidally loaded between 0.1 kN and 3.1 kN for 10 million cycles at 4 Hz. In test 1 rough mini stem tapers were compared with rough standard stem tapers whilst in test 2 rough mini stem tapers were compared with smooth mini stem tapers. Surface parameters and profiles were measured before and after testing. Electrochemical static and dynamic corrosion tests were performed between rough mini stem tapers and smooth mini stem tapers under loaded and non-loaded conditions. Results:. In test 1 following the mechanical loading test the surface roughness parameters on the head taper were significantly increased when they were coupled with the mini stem tapers compared to the standard stem tapers (p = 0.046). Similarly in test 2 the surface roughness parameters on the head tapers were significantly increased when mini rough stem tapers were used compared to smooth mini stem tapers (p = 0.04). Corrosion testing showed breaching of the passive film on the rough but not the smooth neck tapers. Conclusion:. This study has identified enhanced fretting corrosion at the modular taper junction associated with roughened surface finish and small neck tapers and points to the overall concern associated with the use of modular taper connections in orthopaedic implants. Crevice corrosion is identified as the predominant mechanism, with evidence of pitting in all rough mini neck tapers. The greatest wear and corrosion was in the plane where the greatest bending moments were generated, implicating fretting as a mechanism. The rough mini neck tapers have a reduced surface area at the interface and ultimately bending forces are concentrated here

Adhered bacteria on titanium surfaces are able to decrease its corrosion potential and impedance values at the lowest frequencies. This result points to the detrimental influence of the biofilm on the passive film formed on the surfaces, independently on the surface finishes. Titanium is one of the most used metallic biomaterials for biological and implant applications. The spontaneous formation of a protective passive film around 2–5 nm thick, make titanium unique as a biomaterial for implants. Its composition has been described by a three-layer model: TiO2/Ti2O3/TiO and its stability is ultimately responsible for the success of osseointegrated titanium implants. The cases of breakdown of the protective passive film are associated with highly acidic environments induced by bacterial biofilms and/or inflammatory processes that lead to localized corrosion of titanium and, in extreme cases, implant failure. Bearing in mind that the surface design of a titanium implant is a key element involved in the healing mechanisms at the bone-implant interface, the surface modifications have sought to enhance the biomechanical anchorage of the implant and promote osseointegration at the cell-biomolecular level. However, little attention has been paid to the effects of these surface modifications in the microbiologically induced corrosion (MIC). The aim of this work is to evaluate the potential for MIC of titanium in the short term under viable bacterial cells of Streptococcus mutansas a representative microorganism of oral biofilm considered to be a highly cariogenic pathogen. Discs of 64 mm. 2. surface area of commercially pure titanium, grade 4, were supplied by Biotechnology Institute (BTI, Vitoria, Spain). Four surface treatments were studied: two acid etchings (low roughness, opN and high roughness, opV). In addition, acid etched plus anodic oxidation (opNT). For comparative purposes, two surface finishes have been included: high roughness – corresponding with sandblasting-large grit plus acid (SLA); and, as-machined titanium (mach). The oral strain used for assessing the biofilm formation on the corrosion behavior of Ti surfaces was Streptococus mutansATCC 25175, obtained from the Spanish Type Culture Collection (CECT). The study of MIC from Streptococcus mutanson surfaces of Ti was carried out in an electrochemical cell specifically designed and patented by some of the present authors [1]. A three set up configuration of the electrochemical cell was used in the experiments. The measurement of the corrosion potential and electrochemical impedance was performed at different periods of incubation of bacteria: 2, 7, 15, 21 and 28 days. Out Slight but continuous decrease in the corrosion potential and impedance values at the lowest frequencies indicate the deleterious influence of the biofilm on the passive film formed on the surfaces, independently on the surface finishes. This research suggests that the most appropriate surface modification for the dental implant portion at the bone level would be the acid etched of high roughness (opV) surface

It is well established in the literature that the tribological properties of sliding metallic and ultra-high molecular weight polyethylene (UHMWPE) counterfaces are a major contributor to accelerate wear rates that contribute to osteolysis. The majority of the research over the years has been on improving the UHMWPE properties through manufacture and secondary processing of the polymer. Little attention has been directed towards the optimisation of the Chromium Cobalt Molybdenum (CrCoMo) surface finish. The focus of this research has been on the highly polished CrCoMo metallic surface. A new surface finishing technique was applied to CrCoMo femoral knee prosthetic implants. The surface finish of our finished implants was compared to that finished by traditional mechanical polishing techniques. A representative number of polished CrCoMo knee femoral components were compared under the following topics; tribological, topographical and the extent of processing containments present. It was found that traditional mechanically polished parts contained a significant amount of embedded polishing compounds (Al2O3), coarse interdendritic (M7C3) and fine (M23C6) carbide elements. Both the polishing containments and carbide elements stand proud of the articulating surface and thus act as micro cutting tools to accelerate UHMWPE wear. The new polishing technique completely eliminated hard carbide particles and embedded polishing compound media. Consequently, the samples prepared using the new polishing technique produced lower UHMWPE wear debris and improved wear patterns to that of the traditionally polished samples. Additionally, all sub-micron scratching was removed from the surface of the samples. This polishing technique for CrCoMo prosthesis represents a milestone in CrCoMo surface finishing and will significantly reduce the UHMWPE wear debris generated and consequently increasing prosthesis longetivity

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