Summary Statement. Fretting and corrosion has been identified as a clinical problem in modular metal-on-metal THA, but remains poorly understood in modern THA devices with polyethylene bearings. This study investigates taper damage and if this damage is associated with polyethylene wear. Introduction. Degradation of modular head-neck tapers was raised as a concern in the 1990s (Gilbert 1993). The incidence of fretting and corrosion among modern, metal-on-polyethylene and ceramic-on-polyethylene THA systems with 36+ mm femoral heads remains poorly understood. Additionally, it is unknown whether metal debris from modular tapers could increase wear rates of highly crosslinked PE (HXLPE) liners. The purpose of this study was to characterise the severity of fretting and corrosion at head-neck modular interfaces in retrieved conventional and HXLPE THA systems and its effect on penetration rates. Patients & Methods. 386 CoCr alloy heads from 5 manufacturers were analyzed along with 166 stems (38 with ceramic femoral heads). Metal and ceramic components were cleaned and examined at the head taper and stem taper by two investigators. Scores ranging from 1 (mild) to 4 (severe) were assigned in accordance with the semi-quantitative method adapted from a previously published technique. Linear penetration of liners was measured using a calibrated digital micrometer (accuracy: 0.001 mm). Devices implanted less than 1 year were excluded from this analysis because in the short-term, creep dominates penetration of the head into the liner. Results. The majority of the components were revised for instability, infection, and loosening. Mild to severe taper damage (score ≥2) was found in 77% of head tapers and 52% of stem tapers. The extent of damage was correlated to implantation time at the head taper (p=0.0004) and at the stem taper (p=0.0004). Damage scores were statistically elevated on CoCr heads than the matched stems (mean score difference=0.5; p<0.0001) and the two metrics were positively correlated with each other (ρ=0.41). No difference was observed between stem taper damage and head material (CoCr, ceramic) (p=0.56), nor was a correlation found between taper damage and head size (p=0.85). The penetration rate across different formulations of HXLPE was not found to be significantly different (p=0.07), and therefore grouped together for further analysis. Within this cohort, penetration rate was not found to be associated with head size (p=0.08) though a negative correlation with implantation time was noted (ρ=−0.35). When analyzed along with taper damage scores, a correlation was not observed between head taper damage scores and HXLPE penetration rates (p=0.51). Discussion. The results of this study do not support the hypothesis that 36+ mm ceramic or CoCr femoral heads articulating on HXLPE liners are associated with increased risk of corrosion among HXLPE liners when compared with smaller diameter heads. A limitation of this study is the semi-quantitative scoring technique, heterogeneity of the retrieval collection and short implantation time of the larger diameter heads. Because corrosion may increase over time in vivo, longer-term follow-up, coupled with quantitative taper wear measurement, will better assess the natural progression of taper degradation in modern THA bearings

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

Revision total hip arthroplasty (THA) presents with increasing challenges, potentially compromising the integrity of a revision. The objective of this study was to assess radiologic outcomes of patients who underwent revision THA with a modular tapered stem (Reclaim, DePuy Synthes). This study retrospectively examined all revision Reclaim THAs between 2012 and 2016. Radiologic assessment compared x-rays at two time points: immediately after surgery and the most recent x-ray available. Leg length discrepancy, subsidence and line-to-line fit was assessed. Significant subsidence was considered ≥10mm. Adequate line-to-line fit was considered ≥30mm of bicortical contact. Descriptive statistics included clinical factors (i.e. age, Paprosky classification). P values <0.05 were considered significant. A total of 81 femoral revisions were completed. There were 42 females and 38 males with a mean age of 71 years (range, 46–89). Of these, 6 were revised (dislocation, fracture or infection), and 7 were lost to follow up. Average follow up time was 18 months (range, 1–46 months). Femoral revisions were classified as Paprosky 3a or 3b. Mean stem subsidence was 4.15mm (range, 0–25.6mm). Subsidence of the femoral stem was <10mm in 88% of patients. A total of 62% of patients had both subsidence <10mm and ≥30mm of bicortical contact. In patients with <10mm subsidence, 70% had ≥30mm of bicortical contact. There was a positive trend between cortical contact and stem stability (OR 2.3). The Reclaim modular femoral system has demonstrated radiographic stability. Inadequate initial fit is a potential determinant of subsidence

We have previously observed an increase in total bone mineral density and reduced bone turnover (TRAP5b and osteocalcin) in patients with well-functioning metal-on-metal hip resurfacing (MOMHR). Here, we provide data to support the hypothesis that osteoclast differentiation and function is altered in this patient population, and that this effect is transferrable through their serum. Patients with well-functioning MOMHR (cases, n=18) at a median follow-up of 8 years were individually matched for gender, age and time-since-surgery to a low-exposure group consisting of patients with THA (controls, n=18). The monocyte fraction of patient peripheral blood was isolated and differentiated into osteoclasts on dentine wafers using RANKL and M-CSF supplemented media (osteoclastogenic media, OM). Cultures were monitored for the onset of resorption, at which point the cells were treated with OM, autologous serum or serum from matched MOMHR/THA donors, all supplemented with RANKL and M-CSF. At the end of the culture, cells were TRAP-stained and quantified using CellD Software Package, Olympus. When cells were differentiated in standard osteoclastogenic media, the resorbing ability of osteoclasts derived from MOMHR patients was reduced 22%(p<0.0079) compared to THA. The resorbing ability of osteoclasts generated from MOMHR patients and differentiated in autologous serum was reduced 33%(p<0.0001), whilst matched THA serum caused a smaller reduction of 14%(p<0.01). When cells derived from THA patients were differentiated in autologous serum, the resorbing ability of osteoclasts was similarly reduced by 35%(p<0.0001), whilst the matched MOMHR serum also caused a reduction of 21%(p<0.0001). This data suggests that prior exposure to higher circulating Co and Cr in patients with MOMHR reduces osteoclastogenesis, and that the detrimental effect on the functionality of mature osteoclasts is transferable through the serum. This has implications for systemic bone health of patients with MOMHR or modular taper junctions

Objectives

Taper junctions between modular hip arthroplasty femoral heads and stems fail by wear or corrosion which can be caused by relative motion at their interface. Increasing the assembly force can reduce relative motion and corrosion but may also damage surrounding tissues. The purpose of this study was to determine the effects of increasing the impaction energy and the stiffness of the impactor tool on the stability of the taper junction and on the forces transmitted through the patient’s surrounding tissues.