Adverse local tissue reactions (ALTR), such as so-called pseudotumours associated with metal-metal bearings, can also occur secondary to corrosion products from modular tapers where at least one side is composed of cobalt alloy. In 1988, Svensson et al. reported a fulminant soft-tissue pseudotumour following a cementless, metal-on-polyethylene total hip. This case had all of the features of ALTR that were subsequently observed in association with contemporary large diameter metal-metal bearings, having the same histological characteristics that Willert and colleagues termed ALVAL in 2005.

There is a documented increased risk of femoral taper corrosion in association with larger diameter (>32 mm) metal-metal bearings. There may be a generic increase in the risk of taper corrosion with larger diameter bearings, regardless of acetabular bearing type. Other variables include the design and manufacturing tolerances of the taper and head, the stiffness of the neck, implantation time, and possibly in vivo assembly. Head and neck moment arm and neck length have not been demonstrated to be independent risk factors for taper corrosion or fretting. Retrieval analyses indicate that fretting and corrosion tend to be higher on the head than on the stem. ALTR has similarly been described in association with corrosion of the modular neck-stem junction. Taper corrosion is the probable explanation for elevated ion levels and ALTR in association with well-positioned metal-metal total hip bearings and low bearing wear. Whole blood or serum metal levels are elevated with a greater elevation of cobalt compared to chromium. Ion analyses are now relatively accessible and reliable and should be obtained in the evaluation of a painful total hip without an obvious cause. Cross-sectional imaging, such as a MARS MRI scan, can demonstrate associated changes in the periprosthetic tissues and secure the diagnosis.

Treatment recommendations are similar to those established for hips with metal-metal bearings and ALTR. Removal of the modular cobalt alloy head and/or neck component is recommended. At this time, there are no established criteria for the degree of “acceptable” femoral taper damage. The dilemma faced by the revising surgeon is whether to expose the patient to the potential morbidity associated with revision of a well-fixed femoral stem, particularly a distally-fixed, extensively porous-coated stem, in the setting of mild-to-moderate fretting and corrosion of the femoral taper. Several manufacturers offer ceramic heads with a titanium alloy taper sleeve inside the head specifically for mating to previously used femoral tapers. It is not recommended to put a ceramic head taper directly onto a used femoral taper. Surface damage of the used femoral taper can create high localised stresses in the ceramic head and predispose to head fracture. The same principles can be applied to corrosion of a stem-neck taper. If the modular neck is made of cobalt alloy, it is preferable to exchange it for one made of titanium alloy (if available). Again, there are no established criteria for the degree of “acceptable” femoral taper damage. The paucity of reported experience with such revisions inhibits further comment at this time.

It is prudent to be suspicious of “taperosis” considering that the majority of heads used over the past 5 years are cobalt alloy and >36 mm in diameter, many contemporary stems have narrower, and hence more flexible necks, some tapers are smaller (shorter), more variable in vivo assembly secondary to “minimally invasive” surgical techniques, and the risk of taper corrosion increases with time in situ. Additional studies are needed to determine the incidence of clinically significant taper corrosion. There are more than 30 different head-stem tapers worldwide and the incidence of clinically significant taper corrosion is likely variable for different head-stem combinations. Similar to ALTR that occur with metal-metal bearings, some cases of ALTR secondary to taper corrosion may be asymptomatic.

Corrosion at metal/metal modular interfaces in total hip arthroplasty was first described in the early 1990's, and the susceptibility of modular tapers to mechanically assisted crevice corrosion (MACC), a combination of fretting and crevice corrosion, was subsequently introduced. Since that time, there have been numerous reports of corrosion at this taper interface, documented primarily in retrieval studies or in rare cases of catastrophic failure.

We have reported that fretting corrosion at the modular taper may produce soluble and particulate debris that can migrate locally or systemically, and more recently reported that this process can cause an adverse local tissue reaction. Based on the type of tissue reaction and the presence of elevated serum metal ion levels, this process appears quite similar to adverse local tissue reactions secondary to metal-on-metal bearing surfaces. While modularity in THR has demonstrable clinical benefits, modular junctions increase the risk of corrosion and the types of adverse soft tissue reactions seen in patients with accelerated metal release from metal-on-metal bearing THRs.