Tribo-chemical damage of modular taper junctions is often observed at revision THR and may be a contributing factor to chronic inflammation of peri-prosthetic tissues through generation of chromium rich corrosion products. At the time of revision, surgeons may elect to leave the primary femoral stem in situ and replace the original femoral head with a new component. This decision is based on the assumption that the interface formed between the original trunnion and the new bore is capable of withstanding the loads and torques applied during use, without failure of the new interface. This study was performed to determine the extent to which the mechanical properties of the taper interface are degraded with varying degrees of tribo-chemical damage secondary to prior implantation. Fifteen CoCr femoral heads (DePuy: 6, Smith & Nephew: 5; Zimmer: 4) were retrieved at revision THR and were examined with stereomicroscopy. The surface of each bore was scored for the presence of fretting and corrosion using the grading system of Goldberg et al. Nine additional heads in original (unimplanted) condition (3 per manufacturer) were also selected to act as controls. Each head was manually assembled on a matching unimplanted TiAlV trunnion in a mechanical testing machine (MTS Bionix) and loaded at 500N/sec to a maximum assembly load of 4000N. The head/trunnion specimen was then mounted in a torsional loading fixture and immersed in bovine serum. A cyclic torque was applied to the head with an initial maximum value of 2 Nm. The specimen was unloaded and held for a 30 sec wait period and the torsional loading was repeated to a peak value of 4 Nm. With each torsional cycle the peak torque was increased by 2 Nm until the taper junction underwent rotational failure. During testing, relative motion between the femoral head and the trunnion was measured with a displacement transducer (DVRT-3, MicroStrain, accuracy = ± 0.1%, resolution = 1.5 μm, hysteresis & repeatability = ± 1 μm). A separate disassembly test was performed by first assembling each specimen with 4000N and then applying a distraction force at 0.008 mm/sec until separation.Introduction
Materials and Methods
The articulating surface replacement (ASR) XL stemmed total hip replacement and ASR resurfacing hip systems were recalled by DePuy due to a high prevalence of early failure. The ASR XL has a greater failure rate than the ASR resurfacing, which has been increasingly attributed to wear and corrosion at the taper interface between the female taper surface of the femoral head and the male taper (trunnion) of the femoral stem. The aim of this study was to quantify the prevalence and severity of taper corrosion in retrieved ASR XL hip components. A peer-reviewed subjective corrosion scoring system was used to quantify corrosion in a consecutive series of the 50 ASR XL hip components (head components – n=44; femoral stems – n=6) at our retrieval centre. Bearing surface wear (femoral head and acetabular cup combined) was quantified and a value of <5 microns was defined as low-wearing. Subsequent profilometry analysis was undertaken in the low-wearing hips to quantify material loss from the taper interface. 90% of components showed evidence of corrosion, with at least moderate corrosion observed in 58%. There were 17 low-wearing hips which had a median material loss from the taper interface of 3.51mm3 (range: 0.612–9.443). The median linear depth of material loss was 33μm (range: 8.5–78.0). No relationship was observed between taper corrosion and serum cobalt (r=0.204, p=0.2712) or chromium (r=0.146, p=0.432) metal ions. Wear and material loss from metal-on-metal (MoM) hips is associated with pseudotumour formation and adverse soft-tissue reactions. We have shown that taper corrosion is extremely common in failed ASR XL hips and that wear occurs in the same degree of magnitude as at the bearing surface also occurs at the taper interface. Therefore our findings support the emerging concept of ‘taper failure’, whereby the taper is the predominate reason for failure of MoM hips. Future work must determine the relative contributions of the bearing surface and the taper interface to serum cobalt and chromium metal ion levels.
Corrosion at the taper interface between the femoral head and the femoral stem is well described in metal-on-polyethylene (MoP) hips but previously was undetermined in large diameter head metal-on-metal (LHMoM) hips. The high failure rate of the articulating surface replacement (ASR) XL hip system has been partly attributed to susceptibility to corrosive damage at the taper interface. It was not known if other hip manufacturers are liable to taper corrosion. Therefore the aim of this study was to quantify the prevalence and severity of taper corrosion in LHMoM hips and compare corrosion across five different current generation manufacturers. Taper corrosion was analysed in a consecutive series of the five most common hip types at our retrieval centre: ASR XL, Evidence of corrosion was observed in 86% of components, with at least moderate corrosion observed in 61%. No difference in corrosion was observed between the ASR XL and the other manufacturers (p=0.202). There was still no difference seen when all manufacturers were compared individually (p=0.363). A positive correlation was observed between corrosion and femoral head diameter (r=0.224, p=0.021). However no relationship was observed with implantation time (r=0.163, p=0.118). Our study indicates that taper corrosion is common in LHMoM hips and affects all hip types equally. The clinical significance of this finding is that all hip types will be susceptible to the complications of corrosion, such as third body wear and osteolysis. Furthermore recent reports indicate that corrosive debris released from the taper interface may play a role in the formation of pseudotumours and adverse soft-tissue reactions. We found that larger femoral head sizes showed greater corrosion, which suggests that high torque increases fretting corrosion of the taper interface. Future work must determine the optimum femoral head size and investigate the chemical composition of the corrosive debris.
In metal-on-metal (MoM) total hip arthroplasty, the taper interface is where the femoral head (female taper surface) attaches to the trunnion (male taper) of the femoral stem. Corrosion is well reported in metal-on-polyethylene hips but little is known about taper corrosion in MoM devices. The aim of this study was to quantify corrosion in modern-generation stemmed MoM hip systems and gain insight into the nature of the underlying corrosive attack. Taper corrosion was quantified in 161 failed MoM components (head components n=128; femoral stem n=33) from nine hip types with the use of a qualitative subjective scoring system. An unanticipated finding on preliminary inspection of the hips was a region on the female taper surface that contained ridges that directly corresponded with the ridged microthread on the trunnion. The ridges were not present on unimplanted (control) female taper surfaces and therefore a novel four-scale subjective scoring system was devised to quantify the prevalence and severity of this ‘imprinting’ phenomenon. Evidence of corrosion was observed in 81% (131/161) of components, with at least moderate corrosion observed in 58% (94/161). Corrosion was greater on the female taper surface than on the male taper (p=0.034) and the two scores were associated (r=0.784, p=0.001). Imprinting affected all manufacturers and was observed in 64% (82/128) of head components. The corrosion and imprinting scores were strongly correlated (r=0.694, p=0.001). Corrosion was largely confined to the area of the female taper interface where imprinting had occurred i.e. the region that had been in contact with the trunnion microthread. Scanning electron microscopy showed evidence of fretting corrosion and substantial mechanical wear within the ridged region on the female taper surface. Our study indicates that MoM hips are susceptible to taper corrosion. We believe it occurs by a process of “mechanically-assisted crevice corrosion,” involving the following sequence of events: joint fluid enters the taper junction as a result of pumping of fluid along the machined microthread of the trunnion. This results in galvanic corrosion of the anodic surface (the cobalt-chromium femoral head or taper sleeve). The pattern of corrosion of the head taper is determined by the surface profile of the screw thread of the trunnion, thus leaving an imprinted appearance. Historically the ridged microthread was introduced to trunnions to minimise the risk of burst fracture of ceramic heads. However this study indicates that the ridges are detrimental in MoM hips by causing extensive mechanical wear. Thus the possibility that cobalt-chrome and ceramic femoral head components require different trunnion designs needs urgent investigation.
