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. Methods. In all, six 28 mm and six 36 mm titanium stem-cobalt chrome head pairs with polyethylene sockets were tested in a novel instrumented hip simulator. Samples were tested using simulated gait data with incremental increasing loads to determine corrosion onset load and electrochemical activity. Half of each head size group were then cycled with simulated gait and the other half with gait compression only. Damage was measured by area and maximum linear wear depth. Results. Overall, 36 mm heads had lower corrosion onset load (p = 0.009) and change in open circuit potential (OCP) during simulated gait with (p = 0.006) and without joint movement (p = 0.004). Discontinuing gait’s joint movement decreased corrosion currents (p = 0.042); however, wear testing showed no significant effect of joint movement on taper damage. In addition, 36 mm heads had greater corrosion area (p = 0.050), but no significant difference was found for maximum linear wear depth (p = 0.155). Conclusion. Larger heads are more susceptible to taper corrosion; however, not due to frictional torque as hypothesized. An alternative hypothesis of taper flexural rigidity differential is proposed. Further studies are necessary to investigate the clinical significance and underlying mechanism of this finding. Cite this article: Bone Jt Open 2021;2(11):1004–1016

Objectives. This study aimed to characterise and qualitatively grade the severity of the corrosion particles released into the hip joint following taper corrosion. Methods. The 26 cases examined were CoC/ABG Modular (n = 13) and ASR/SROM (n = 13). Blood serum metal ion levels were collected before and after revision surgery. The haematoxylin and eosin tissue sections were graded on the presence of fibrin exudates, necrosis, inflammatory cells and corrosion products. The corrosion products were identified based on visible observation and graded on abundance. Two independent observers blinded to the clinical patient findings scored all cases. Elemental analysis was performed on corrosion products within tissue sections. X-Ray diffraction was used to identify crystalline structures present in taper debris. Results. The CoC/ABG Modular patients had a mean age of 64.6 years (49.4 to 76.5) and ASR/SROM patients had a mean age of 58.2 years (33.3 to 85.6). The mean time in situ for CoC/ABG was 4.9 years (2 to 6.4) and ASR/SROM was 6.1 years (2.5 to 8.1). The blood serum metal ion concentrations reduced following revision surgery with the exception of Cr levels within CoC/ABG. The grading of tissue sections showed that the macrophage response and metal debris were significantly higher for the ASR/SROM patients (p < 0.001). The brown/red particles were significantly higher for ASR/SROM (p < 0.001). The taper debris contained traces of titanium oxide, chromium oxide and aluminium nitride. Conclusion. This study characterised and qualitatively graded the severity of the corrosion particles released into the hip joint from tapers that had corrosion damage. Cite this article: S. Munir, R. A. Oliver, B. Zicat, W. L. Walter, W. K. Walter, W. R. Walsh. The histological and elemental characterisation of corrosion particles from taper junctions. Bone Joint Res 2016;5:370–378. DOI: 10.1302/2046-3758.59.2000507

The aim of this study was to assess the effect of frictional torque and bending moment on fretting corrosion at the taper interface of a modular femoral component and to investigate whether different combinations of material also had an effect. The combinations we examined were 1) cobalt–chromium (CoCr) heads on CoCr stems 2) CoCr heads on titanium alloy (Ti) stems and 3) ceramic heads on CoCr stems. In test 1 increasing torque was imposed by offsetting the stem in the anteroposterior plane in increments of 0 mm, 4 mm, 6 mm and 8 mm when the torque generated was equivalent to 0 Nm, 9 Nm, 14 Nm and 18 Nm. In test 2 we investigated the effect of increasing the bending moment by offsetting the application of axial load from the midline in the mediolateral plane. Increments of offset equivalent to head + 0 mm, head + 7 mm and head + 14 mm were used. Significantly higher currents and amplitudes were seen with increasing torque for all combinations of material. However, Ti stems showed the highest corrosion currents. Increased bending moments associated with using larger offset heads produced more corrosion: Ti stems generally performed worse than CoCr stems. Using ceramic heads did not prevent corrosion, but reduced it significantly in all loading configurations. Cite this article: Bone Joint J 2015;97-B:463–72

Aims. To present a surgically relevant update of trunnionosis. . Materials and Methods. Systematic review performed April 2017. Results. Trunnionosis accounts for approximately 2% of the revision total hip arthroplasty (THA) burden. Thinner (reduced flexural rigidity) and shorter trunnions (reduced contact area at the taper junction) may contribute to mechanically assisted corrosion, exacerbated by high offset implants. The contribution of large heads and mixed metallurgy is discussed. Conclusion. Identifying causative risk factors is challenging due to the multifactorial nature of this problem. Cite this article: Bone Joint J 2018;100-B(1 Supple A):44–9

We present a series of 35 patients (19 men and 16 women) with a mean age of 64 years (36.7 to 75.9), who underwent total hip replacement using the ESKA dual-modular short stem with metal on-polyethylene bearing surfaces. This implant has a modular neck section in addition to the modular head. Of these patients, three presented with increasing post-operative pain due to pseudotumour formation that resulted from corrosion at the modular neck-stem junction. These patients underwent further surgery and aseptic lymphocytic vaculitis associated lesions were demonstrated on histological analysis. Retrieval analysis of two modular necks showed corrosion at the neck-stem taper. Blood cobalt and chromium levels were measured at a mean of nine months (3 to 28) following surgery. These were compared with the levels in seven control patients (three men and four women) with a mean age of 53.4 years (32.1 to 64.1), who had an identical prosthesis and articulation but with a prosthesis that had no modularity at neck-stem junction. The mean blood levels of cobalt in the study group were raised at 50.75 nmol/l (5 to 145) compared with 5.6 nmol/l (2 to 13) in control patients. Corrosion at neck-stem tapers has been identified as an important source of metal ion release and pseudotumour formation requiring revision surgery. Finite element modelling of the dual modular stem demonstrated high stresses at the modular stem-neck junction. Dual modular cobalt-chrome hip prostheses should be used with caution due to these concerns

Introduction. MDM implants can enhance stability in total hip replacement (THR), but complications include malseated liners and corrosion between the cobalt-chrome liner and titanium acetabular shell increased systemic metal ion levels. The liner-shell junction has the potential for fretting corrosion, and the corrosion could be exacerbated in malseated liners. We determined the potential for fretting corrosion in malseated versus well-seated liners using a mechanical electrochemical corrosion chamber. Methods. Four pristine MDM liners and shells were tested. Two liners were well-seated into their shells; two were canted at 6°. The liner-shell couples were assembled with a 2kN force after wetting the surfaces to promote a crevice environment conducive to corrosion. Couples were fixed in an electrochemical chamber at 40° inclination/20° anteversion to the load axis. The chamber was filled with phosphate buffered saline and setup as a three-electrode configuration: the shell as the working, a saturated calomel electrode as the reference, and a carbon rod as the counter electrode. A potentiostat held the system at −50mV throughout testing. After equilibration, couples underwent cyclic loading of increasing magnitudes from 100 to 3400N at 3 Hz. Fretting current was measured throughout, and the onset load for fretting was determined from the increase in average current. Results. Well-seated liners showed lower fretting current values at all peak compressive loads greater than 800 N (p<0.05). Canted liners demonstrated a fretting onset load of 2400 N, and fretting currents at greater than 2400 N were larger than those at lower peak compressive loads (p<0.05). Conclusion. The clinical consequences of MDM liner malseating remain unknown, but our results demonstrate earlier fretting current onset at lower peak loads when compared to well-seated liners. The onset loads were consistent with physiologic loads for daily activities. Our findings are significant given the potential for metallosis and adverse local tissue reactions. For any tables or figures, please contact the authors directly

Aims. Dual mobility implants in total hip arthroplasty are designed to increase the functional head size, thus decreasing the potential for dislocation. Modular dual mobility (MDM) implants incorporate a metal liner (e.g. cobalt-chromium alloy) in a metal shell (e.g. titanium alloy), raising concern for mechanically assisted crevice corrosion at the modular liner-shell connection. We sought to examine fretting and corrosion on MDM liners, to analyze the corrosion products, and to examine histologically the periprosthetic tissues. Methods. A total of 60 retrieved liners were subjectively scored for fretting and corrosion. The corrosion products from the three most severely corroded implants were removed from the implant surface, imaged using scanning electron microscopy, and analyzed using Fourier-transform infrared spectroscopy. Results. Fretting was present on 88% (53/60) of the retrieved liners, and corrosion was present on 97% (58/60). Fretting was most often found on the lip of the taper at the transition between the lip and the dome regions. Macrophages and particles reflecting an innate inflammatory reaction to corrosion debris were noted in six of the 48 cases for which periprosthetic tissues were examined, and all were associated with retrieved components that had high corrosion scores. Conclusion. Our results show that corrosion occurs at the interface between MDM liners and shells and that it can be associated with reactions in the local tissues, suggesting continued concern that this problem may become clinically important with longer-term use of these implants. Cite this article: Bone Joint J 2021;103-B(7):1238–1246

Aims. This study aims to enhance understanding of clinical and radiological consequences and involved mechanisms that led to corrosion of the Precice Stryde (Stryde) intramedullary lengthening nail in the post market surveillance era of the device. Between 2018 and 2021 more than 2,000 Stryde nails have been implanted worldwide. However, the outcome of treatment with the Stryde system is insufficiently reported. Methods. This is a retrospective single-centre study analyzing outcome of 57 consecutive lengthening procedures performed with the Stryde nail at the authors’ institution from February 2019 until November 2020. Macro- and microscopic metallographic analysis of four retrieved nails was conducted. To investigate observed corrosion at telescoping junction, scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDX) were performed. Results. Adjacent to the nail’s telescoping junction, osteolytic changes were observed in bi-planar radiographs of 20/57 segments (35%) after a mean of 9.5 months (95% confidence interval 7.2 to 11.9) after surgery. A total of 8/20 patients with osseous alterations (40%) reported rest and ambulation pain of the lengthened segment during consolidation. So far, 24 Stryde nails were retrieved and in 20 (83%) macroscopic corrosion was observed at the nail’s telescoping junction. Before implant removal 11/20 radiographs (55%) of lengthened segments with these 20 nails revealed osteolysis. Implant retrieval analysis by means of SEM showed pitting and crevice corrosion. EDX detected chromium as the main metallic element of corrosion. Conclusion. Patients are exposed to the risk of implant-related osteolysis of unclear short- and long-term clinical consequences. The authors advocate in favour of an early implant removal after osseous consolidation. Cite this article: Bone Joint Res 2021;10(7):425–436

Aims. Taper corrosion has been widely reported to be problematic for modular total hip arthroplasty implants. A simple and systematic method to evaluate taper damage with sufficient resolution is needed. We introduce a semiquantitative grading system for modular femoral tapers to characterize taper corrosion damage. Methods. After examining a unique collection of retrieved cobalt-chromium (CoCr) taper sleeves (n = 465) using the widely-used Goldberg system, we developed an expanded six-point visual grading system intended to characterize the severity, visible material loss, and absence of direct component contact due to corrosion. Female taper sleeve damage was evaluated by three blinded observers using the Goldberg scoring system and the expanded system. A subset (n = 85) was then re-evaluated following destructive cleaning, using both scoring systems. Material loss for this subset was quantified using metrology and correlated with both scoring systems. Results. There was substantial agreement in grading among all three observers with uncleaned (n = 465) and with the subset of cleaned (n = 85) implants. The expanded scoring criteria provided a wider distribution of scores which ultimately correlated well with corrosion material loss. Cleaning changed the average scores marginally using the Goldberg criteria (p = 0.290); however, using the VGS, approximately 40% of the scores for all observers changed, increasing the average score from 4.24 to 4.35 (p = 0.002). There was a strong correlation between measured material loss and new grading scores. Conclusion. The expanded scoring criteria provided a wider distribution of scores which ultimately correlated well with corrosion material loss. This system provides potential advantages for assessing taper damage without requiring specialized imaging devices. Cite this article: Bone Joint Res 2023;12(3):155–164

Aims. To report our experience with trunnion corrosion following metal-on-polyethylene total hip arthroplasty, in particular to report the spectrum of presentation and determine the mean time to presentation. Patients and Methods. We report the presenting symptoms and signs, intraoperative findings, and early results and complications of operative treatment in nine patients with a mean age of 74 years (60 to 86). The onset of symptoms was at a mean of seven years (3 to 18) after index surgery. Results. Patients presented with a variety of symptoms including pain, limp and rash. The preoperative mean serum cobalt level was 7.1 ppb (2.2 to 12.8) and mean serum chromium level was 2.2 ppb (0.5 to 5.2). Metal artifact reduction sequence (MARS) MRI showed fluid collection and possible pseudotumour formation in five hips, fluid collection in two hips, and synovitis/debris in one hip, with no MRI in one patient. Acetabular revision was performed in three patients, six patients underwent liner and head exchange only. The postoperative metal levels decreased in all patients: mean cobalt 0.5 ppb (0 to 1.8) and mean chromium 0.9 ppb (0 to 2.6) at a mean of five months (3 to 8) postoperatively. Seven patients had good pain relief and no complications at one year. There were two major complications requiring reoperation: acute infection at six weeks, for which the patient required two-stage reimplantation; and recurrent dislocation, for which the patient was revised to a dual mobility component. Conclusion. Trunnion corrosion in metal-on-polyethylene THA has a range of presenting symptoms, and may present later than previously described. A high index of suspicion is warranted, and serum cobalt and chromium levels are recommended for diagnosis. Patients should be counselled about possible postoperative complications. Cite this article: Bone Joint J 2018;100-B:898–902

There is increasing global awareness of adverse reactions to metal debris and elevated serum metal ion concentrations following the use of second generation metal-on-metal total hip arthroplasties. The high incidence of these complications can be largely attributed to corrosion at the head-neck interface. Severe corrosion of the taper is identified most commonly in association with larger diameter femoral heads. However, there is emerging evidence of varying levels of corrosion observed in retrieved components with smaller diameter femoral heads. This same mechanism of galvanic and mechanically-assisted crevice corrosion has been observed in metal-on-polyethylene and ceramic components, suggesting an inherent biomechanical problem with current designs of the head-neck interface. We provide a review of the fundamental questions and answers clinicians and researchers must understand regarding corrosion of the taper, and its relevance to current orthopaedic practice. Cite this article: Bone Joint J 2016;98-B:579–84

Titanium alloys are one of the most used for orthopaedic implants and the fabrication of them by 3D printing technology is a raising technology, which could effectively resolve existing challenges. Surface modification of Ti surfaces is often necessary to improve biocorrosion resistance, especially in inflammatory conditions. Such modification can be made by coatings based on hydrogels, like alginate (Alg) - a naturally occurring anionic polymer. The properties of the hydrogel can be further enhanced with calcium phosphates like octacalcium phosphate (OCP) as a precursor of biologically formed hydroxyapatite. Formed Alg-OCP matrices have a high potential in wound healing, delivery of bioactive agents etc. but their effect on 3D printed Ti alloys performance was not well known. In this work, Alg-OCP coated 3D printed samples were studied with electrochemical measurements and revealed significant variations of corrosion resistance vs. composition of the coating. The potentiodynamic polarization test showed that the Alg-OCP-coated samples had lower corrosion current density than simple Alg-coated samples. Electrochemical impedance spectroscopy indicated that OCP incorporated hydrogels had also a high value of the Bode modulus and phase angle. Hence Alg-OCP hydrogels could be highly beneficial in protecting 3D printed Ti alloys especially when the host conditions for the implant placement are inflammatory. AcThis work was supported by the European Union Horizon 2020 research and innovation programme under the Marie Skłodowska-Curie Actions GA860462 (PREMUROSA). The authors also acknowledge the access to the infrastructure and expertise of the BBCE – Baltic Biomaterials Centre of Excellence (European Union Horizon 2020 programme under GA857287)

INTRODUCTION. Mechanically assisted crevice corrosion of taper interfaces was raised as a concern in total hip arthroplasty (THA) approximately 20 years ago (Gilbert 1993). In total shoulder replacement, however, comparatively little is known about the prevalence of fretting assisted crevice corrosion or the biomechanical and patient factors that influence this phenomenon. Given the comparatively lower loading experienced in the shoulder compared to the hip, we asked: (1) What is the prevalence of fretting assisted corrosion in modular total shoulder replacements, and (2) What patient and implant factors are associated with corrosion?. METHODS. Modular components were collected from 48 revision shoulder arthroplasties as part of a multi-center, IRB approved retrieval program. For anatomic shoulders, this included 40 humeral heads, 32 stems and four taper adapters from seven manufacturers. For reverse shoulders, there were eight complete sets of retrieved components from three manufacturers. The components were predominantly revised for instability, loosening and pain. Anatomical shoulders were implanted for an average of 3.1 years (st dev 3.8; range 0.1–14.5). Reverse shoulders were implanted for an average of 2.2 years (st dev 0.7; range 1.3–3.3). Modular components were disassembled and examined for taper damage. The modular junctions were scored for fretting corrosion using a semi-quantitative four-point scoring system adapted from Goldberg, et al. (Goldberg, 2002, Higgs 2013). The scoring system criteria was adapted from Goldberg and Higgs which is comprised of a one to four grading system (with one indicating little-to-no fretting/corrosion and four indicating extensive fretting/corrosion). The component alloy composition was determined using the manufacturer's laser markings and verified by x-ray fluorescence. Patient age, gender, hand dominance, alloy, flexural rigidity of the trunnion and taper geometry were assessed independently as predictors for fretting corrosion. RESULTS. Moderate to severe fretting corrosion (score > 2) was observed in 23% of the anatomic modular components (Figure 1) and 22% of the reverse shoulder components. An example with severe damage is included in Figure 1. There was no significant relation between corrosion scores and any of the assessed factors. DISCUSSION AND CONCLUSION. It has been suggested that fretting assisted crevice corrosion may be a concern in THA, particularly with large head metal-on-metal articulations. We have identified the presence of moderate to severe corrosion on approximately one quarter of all retrieved shoulder arthroplasties. This is similar to the proportion observed in retrieved modular hips (Goldberg, 2002). While the expected loading of the shoulder is less than that in the hip (Westerhoff, 2009), the offset between the effective center of the prosthetic humeral head and the taper connecter is often larger and the size of the taper is smaller. This can increase the effect of bearing surface loading on the taper. We were unable to detect significant associated biomechanical or patient factors. This was probably due to the limited sample size of our population. At the present time, the clinical effects of taper corrosion in shoulder arthroplasty remain unknown

Introduction. Since the introduction of modular hip taper junctions, corrosion has been studied yet the clinical effect remains unclear. Mechanically assisted corrosion and crevice corrosion are thought to be the primary clinical processes driving taper corrosion. Like all corrosion reactions, these processes require the taper junction to be in contact with an electrolyte. This study investigates the effect of sealing the taper junction from the environment on the mechanically-induced corrosion of a modular hip taper junction. Methods. A short-term corrosion fatigue test was conducted with Ti6Al4V 12/14 taper coupons coupled with CoCrMo 12/14 taper 28mm+12 heads (DePuy Synthes, Warsaw, IN). Ten specimens were assembled with a 1.1 kN press load and sealed with silicone sealant (Dow-Corning 732 Multi-Purpose Sealant). Prior to assembly five of these specimens were assembled with the taper junction having been wetted with phosphate buffered saline before assembly; the rest were assembled dry. Specimens were then immersed in phosphate buffered saline and a potentiostat was used to maintain the potential of the specimen at −50mV vs. Ag/AgCl. Incrementally larger loads were applied to the head of the specimen until a 4000N maximum load was reached. The average currents generated during this test was used to assess the corrosion performance of the specimens. The data from the sealed specimens was compared to a control group, which were wetted before assembly but not sealed. Results. In all cases the corrosion of the sealed specimens did not appear to increase in response to the cyclic load; throughout the test, the corrosion did not increase over the baseline anodic current of roughly 0.25 μA. In contrast, the unsealed controls experienced average corrosion currents of around 5 μA at the maximum load, and an average current of 2.0±0.93 µA over the entire test. The wet and dry sealed assembly specimens both resulted in significantly lower average currents of 0.24±0.09 µA and 0.25±0.09 µA, respectively. Discussion. Test specimens with sealed taper junctions to prevent fluid and ion ingress and egress resulted in no measurably increased corrosion currents compared to the baseline currents in the ambient fluid. The wetted sealed specimens might possibly be subject to corrosion; however the corrosion process and effects in this case may be isolated within the taper junction. This test indicates mechanically assisted corrosion does not occur if the taper junction is not exposed to an electrolyte. Significance. This study demonstrates that mechanically induced corrosion can be greatly reduced or prevented by sealing the taper junction to prevent the ingress of electrolyte

Introduction. Fretting crevice-corrosion (tribocorrosion) of metallic biomaterials is a major concern in orthopedic, spinal, dental and cardiovascular devices. 1. Stainless steel (i.e., 316L SS) is one alloy that sees extensive use in applications where fretting, crevices and corrosion may be present. While fretting-corrosion of this alloy has been somewhat studied, the concept of fretting-initiating crevice corrosion (FICC), where an initial fretting corrosion process leads to ongoing crevice-corrosion without continued fretting, is less understood. This study investigated the susceptibility of 316L SS to FICC and the role of applied potential on the process. The hypothesis is crevice-corrosion can be induced in 316L SS at potentials well below the pitting potential. Materials and Methods. A pin-on-disk fretting test system similar to that of Swaminathan et al. 2. was employed. Disks were ∼35 mm in diameter and the pin area was ∼500 mm. Samples were polished to 600 mm finish, cleaned with ethanol and distilled water. An Ag/AgCl wire as the reference, a carbon counter electrode and phosphate buffered saline (PBS, pH 7.4, Room T) were used for electrochemical testing. Load was controlled with a dead-weight system, monitored with a six-axis load cell (ATI Inc.). Interfacial motion was captured with a non-contact eddy current sensor (0.5 mm accuracy). Motion and load data acquisition was performed with Labview (National Instruments). Samples were loaded to ∼2 N. The potential per tests was increased from −250 to 250 mV (50 mV increments) with new locations and pins used in each repeat (n=3). Testing incorporated a 1 min rest before fretting (5 min, 1.25 Hz, 60 mm displacement saw tooth pattern). Fretting ceased and the load was held while currents were captured for another 5 min to assess ongoing crevice corrosion. Results. Testing showed that crevice corrosion can be initiated within minutes of fretting (or in a few cycles depending on potential; Fig. 1). Potentials as low as −100 mV showed evidence of corrosion, while sustained crevice corrosion was seen at −50 mV. As the potential increased above −50 mV, susceptibility to FICC increased. Fig. 2 is a typical cyclic polarization curve for 316L SS in PBS without fretting. Pitting starts at 400 mV vs Ag/AgCl, and the protection potential in this case is around potentials where FICC can be induced. Discussion. This study showed that 316L SS is prone to FICC starting at −100 mV and the severity of the crevice-corrosion damage depends on the applied potential (Fig. 3). Current after cessation of fretting takes longer to return to baseline or does not return indicating ongoing corrosion without fretting (Fig. 1). If the pin and disk are separated, the crevice-corrosion process stops immediately. The region immediately outside the fretting contact was crevice-like with a very small separation distance between the pin and disk surface which allowed crevice corrosion to develop (Fig. 3). Conclusion. 316L SS can undergo FICC at potentials close to normal physiological electrode potential conditions. Few fretting cycles are required to develop conditions for continued crevice-corrosion. Higher potentials increased the susceptibility of FICC in 316L SS

Aims. The purpose of this study was to directly compare the Modular Dual Mobility (MDM) Mobile Bearing Hip System (Stryker, USA) and large femoral heads (LFHs) in revision total hip arthroplasties (THAs) at mid-term follow-up, with specific emphasis on survival free of re-revision for dislocation, any re-revision, dislocation, and the risk of metal-related complications. Methods. We identified 299 revision THAs performed at a single tertiary care academic institution from March 2011 to July 2014. Aseptic loosening of the acetabular component (n = 65), dislocation (n = 58), and reimplantation as part of a two-stage exchange protocol (n = 57) were the most common reasons for index revision. MDM constructs were used in 123 cases, and LFHs were used in 176 cases. Mean age was 66 years (28 to 93), mean BMI was 31 kg/m. 2. (18 to 55), and 45% (n = 136) were female. Mean follow-up was seven years (2 to 12). Results. The ten-year survival free of re-revision for dislocation was 99% (95% CI 95 to 100) in the MDM cohort and 91% (95% CI 84 to 96) in the LFH cohort, with a significantly increased risk of re-revision for dislocation in the LFH cohort (HR 7.1 (95% CI 1.3 to 40.8); p = 0.023). The ten-year survival free of any re-revision was 92% (95% CI 82 to 99%) in the MDM cohort and 84% (95% CI 74 to 90) in the LFH cohort with a significantly increased risk of any re-revision in the LFH cohort (HR 2.6 (95% CI 1.1 to 5.9); p = 0.024). The ten-year survival free of any dislocation was 95% (95% CI 85 to 99) in the MDM cohort and 87% (95% CI 78 to 92) in the LFH cohort with a significantly increased risk of any dislocation in the LFH cohort (HR 2.7 (95% CI 1.1 to 6.3); p = 0.028). There were no re-revisions or reoperations for metallosis or corrosion in the MDM cohort. Conclusion. In this head-to-head comparison, revision THAs with a MDM construct safely and effectively lowered the risk of re-revision for dislocation, any re-revision, and any dislocation compared to LFH at mid-term follow-up. There were no re-revisions or reoperations for metallosis or corrosion in the MDM cohort. Cite this article: Bone Joint J 2025;107-B(1):58–64

Little is known about the relationship between head-neck corrosion and its effect on the periprosthetic tissues and distant organs of patients hosting well-functioning devices. The purpose of this study was to investigate in postmortem retrieved specimens the degree and type of taper damage, and the corresponding histologic responses in periprosthetic tissues and distant organs. Fifty postmortem THRs (34 primaries, 16 revisions) retrieved after 0.5 to 26 years were analyzed. Forty-three implants had a CoCrMo stem and seven had a Ti6Al4V stem. All heads were CoCrMo and articulated against polyethylene cups (19 XLPE, 31 UHMWPE). H&E sections of joint pseudocapsules, liver, spleen, kidneys and lymph nodes were graded 1–4 for the intensity of various inflammatory cell infiltrates and tissue characteristics. Corrosion damage of the taper surfaces was assessed using visual scoring and quantitated with an optical coordinate measuring machine. SEM analysis was used to determine the acting corrosion mode. Polyethylene wear was assessed optically. The majority of tapers had minimal to mild damage characterized by local plastic deformation of machining line peaks. Imprinting of the stem topography onto the head taper surface was observed in 18 cases. Column damage on the head taper surface occurred in three cases. All taper surfaces scored moderate or severe exhibited local damage features of fretting and/or pitting corrosion. Moderate or severe corrosion of the head and/or trunnion was present in nine hips. In one asymptomatic patient with bilateral hips, lymphocyte-dominated tissue reactions involving perivascular infiltrates of lymphocytes and plasmacytes were observed. In this patient, mild, focal lymphocytic infiltrates were also present in the liver and kidneys, and there was focal histiocytosis and necrosis of the para-aortic lymph nodes. These two implants, which had been in place for 58.6 and 60.1 months, had severe intergranular corrosion of the CoCrMo trunnion, and column damage and imprinting on the head taper. In the other 41 hips, macrophage responses in the joint pseudocapsule to metallic and/or polyethylene wear particles ranged widely from minimal to marked. Focal necrosis in the pseudocapsules of 12 arthroplasties was related to high concentrations of CoCrMo, TiAl4V, TiO, BaSO4 and polyethylene wear particles. High concentrations of these particles were also detected in para-aortic lymph nodes. Rare to mild macrophages were observed in liver and spleen. This is a comprehensive study of wear and corrosion within well-functioning postmortem retrieved THRs, and the resulting local and distant tissue reactions. One of eight patients with moderate or severe corrosion did have a subclinical inflammatory response dominated by lymphocytes after five years. To what extent such an inflammatory process might progress to become symptomatic is not known. Ionic and particulate products generated by corrosion disseminated systemically. The minor lymphocytic infiltrate in the liver and kidneys of one subject with bilateral severely corroded head-neck junctions might suggest possible metal toxicity. The diagnosis of adverse tissue reactions to corrosion of modular junctions can be challenging. Postmortem retrieval studies add to our understanding of the nature and progression of lymphocyte-dominated adverse local and potentially systemic tissue reactions to corrosion of modular junctions

Summary. Corrosion and fretting damage at the head-neck interface of artificial hip joints is more severe with larger head sizes. This is a concern, as the release of metal particles and ions can cause adverse tissue reactions, similar to those observed high wear metal-on-metal articulations. Introduction. In the last few years corrosion was increasingly observed at head-neck interfaces of artificial hip joints, especially in joints with larger heads. There has always been evidence of some corrosion at modular junctions of artificial joints, but except for few designs, it was not seen as a real problem. It is important to better understand the factors contributing to corrosion at modular interfaces, so that necessary improvements can be made to minimise or completely avoid corrosion, in order to avoid possible adverse tissue reactions. Methods. Over 100 retrieved stems and heads of 28, 32, 36, 40 and larger heads with metal-on-polyethylene (MoP) and metal-on-metal (MoM) articulations were scored for corrosion and fretting damage, in order to get a better picture of the magnitude of the problem. For some of the head sizes it was possible to assess the fretting and corrosion damage separately from implants from two different manufacturers. The tapers of the stem and head were subdivided into eight regions each, and scored for the severity of fretting and corrosion damage, as well as of the affected area within each sub-section. The scoring was undertaken by three persons with a fair intraclass correlation. The fretting and corrosion scores were also assessed based on the location of the center of the head with respect to the center of the taper. The distance between these two centers influences the toggling motion between the head and neck, as the main load is about 30 degrees out of axis during walking and other activities of daily living. Results. It was found that head-neck interfaces of two manufacturers of 36mm heads had significantly more corrosion than 28mm heads. There is a significant relationship between head and neck fretting damage, and between corrosion and fretting damage. There is also more corrosion damage in 32, 40 and larger heads, but these groups were from different manufacturers, so that it was not possible to perform statistical tests. More corrosion was observed when the centre of the head was at a larger distance from the centre of the head, leading to an increased toggling moment due to the out-of-axis loading. Discussion. It is of some concern that more corrosion is being observed with larger heads. Corrosion generally gets worse over time, which could negatively impact on the long-term behavior of these hip joints. Furthermore, it is possible that the metal particle and ion release due to corrosion and fretting could have adverse soft tissue reactions, similar to those observed at some MoM articulations. The fact that there are significant differences in the observed corrosion and fretting damage between the head-neck interfaces of two companies, indicates that even subtle changes in the geometry and the machined taper surface are important. A better understanding of these factors is required to make sure that the corrosion and fretting damage is minimised, or even better eliminated for all heads of artificial joints

Uncemented metal-on-polyethylene total hip arthroplasties (THAs) have had a modular cobalt-chrome alloy head since their introduction in the early 1980's. Retrieval analysis studies and case reports in the early 1990's first reported corrosion between the femoral stem trunnion (usually titanium alloy) and cobalt-chrome alloy femoral head. However, then this condition seemed to disappear for about two decades? There are now numerous recent case series of this problem after metal-on-polyethylene THA, with a single taper or dual taper modular femoral component. Metal ion elevation, corrosion debris, and effusion are caused by mechanically assisted crevice corrosion (MACC). These patients present with diffuse hip pain, simulating trochanteric bursitis, iliopsoas tendinitis, or even deep infection. Trunnion corrosion, with adverse local tissue reaction, is a diagnosis of exclusion, after infection, loosening, or fracture. The initial lab tests recommended are: ESR, CRP, and serum cobalt and chromium ions. With a metal-on-polyethylene THA, a cobalt level > 1ppb is abnormal. Plain radiographs are usually negative, but may show calcar osteolysis or acetabular erosion or cyst. MARS MRI may be the best imaging study to confirm the diagnosis. Hip aspiration for culture and cell-count may be necessary. The operative treatment is empiric, with debridement, and head exchange with a ceramic head-titanium sleeve (or oxidised zirconium head) placed on the cleaned trunnion. The femoral component may have to be removed if there is “whole trunnion failure”. This usually relieves the symptoms, but the complication rate of this procedure may be high

Aims. This combined clinical and in vitro study aimed to determine the incidence of liner malseating in modular dual mobility (MDM) constructs in primary total hip arthroplasties (THAs) from a large volume arthroplasty centre, and determine whether malseating increases the potential for fretting and corrosion at the modular metal interface in malseated MDM constructs using a simulated corrosion chamber. Methods. For the clinical arm of the study, observers independently reviewed postoperative radiographs of 551 primary THAs using MDM constructs from a single manufacturer over a three-year period, to identify the incidence of MDM liner-shell malseating. Multivariable logistic regression analysis was performed to identify risk factors including age, sex, body mass index (BMI), cup design, cup size, and the MDM case volume of the surgeon. For the in vitro arm, six pristine MDM implants with cobalt-chrome liners were tested in a simulated corrosion chamber. Three were well-seated and three were malseated with 6° of canting. The liner-shell couples underwent cyclic loading of increasing magnitudes. Fretting current was measured throughout testing and the onset of fretting load was determined by analyzing the increase in average current. Results. The radiological review identified that 32 of 551 MDM liners (5.8%) were malseated. Malseating was noted in all of the three different cup designs. The incidence of malseating was significantly higher in low-volume MDM surgeons than high-volume MDM surgeons (p < 0.001). Pristine well-seated liners showed significantly lower fretting current values at all peak loads greater than 800 N (p < 0.044). Malseated liner-shell couples had lower fretting onset loads at 2,400 N. Conclusion. MDM malseating remains an issue that can occur in at least one in 20 patients at a high-volume arthroplasty centre. The onset of fretting and increased fretting current throughout loading cycles suggests susceptibility to corrosion when this occurs. These results support the hypothesis that malseated liners may be at risk for fretting corrosion. Clinicians should be aware of this phenomenon. Cite this article: Bone Joint J 2020;102-B(7 Supple B):20–26