Introduction. Wear of the UHMWPE tibial component remains a major reason for aseptic loosening and subsequent revision or failure of TKAs [1]. Many retrieval studies measure surface damage patterns as surrogates for the severity of wear, but little is known about how these patterns relate to the volume of material lost. This study (a) examines the wear rate of a cruciate retaining TKA design and (b) relates observed wear patterns to volume loss on the surface. We hypothesize that damage patterns are good predictors for volumetric wear. Methods. 43 revision and 21 postmortem-retrieved MG II (Zimmer Inc.) tibial UHMWPE components were included in this study. Wear scars and damage patterns on the superior articular surfaces were digitized using a video microscope (SmartScope, OGP). Patterns were parsed into four spatially exclusive categories: delamination, polishing, striations and pitting. The surfaces were measured at 100×100µm using a low-incidence laser on a coordinate measuring machine (SmartScope, OGP). Autonomous mathematical reconstruction of the original surface was used [2] to calculate volume changes on the medial and lateral surfaces as an estimate of wear volume [Fig. 1] Total volume loss was calculated within the observed wear scar, and volume loss under each pattern was calculated and normalized to the total volume loss of its insert. Results. Excluding delaminated components, total wear correlated linearly with time in situ (Pearson's r=0.53) with a volumetric wear rate of 13.0±2.9 mm. 3. /year. Total wear area correlated linearly with total wear volume (Pearson's r=0.44), while delaminated area correlated strongly with total wear volume (Pearson's r=0.80). Excluding delaminated components, striated areas correlated more strongly to total volume loss (Pearson's r=0.54) than did total wear scar area (Pearson's r=0.34), while other patterns showed no correlation [Fig. 2]. When present, delaminated areas contributed most to total volume loss in postmortem- and revision-retrievals (58.3% and 38.7% respectively), striations second most (36.2% and 30.7%) and polished areas third most (24.6% and 27.6%), although significant differences were not observed [Fig. 3]. Pitted areas contributed significantly less (heteroscedastic t-test p=0.010) to total wear on postmortem- (1.3±1.7%) than on revision-retrievals (11.3±19.6%), although they were observed with a slightly higher frequency in the postmortem group (81% vs. 76%). Discussion. We found that damage patterns were not reliable surrogates for material volume loss. Other than delamination, area of striated patterns best predicted and contributed most to volume loss. Furthermore, our data suggests that polished and striated patterns in the absence of pitting are markers of a well-functioning UHWMPE TKR. While other groups have reported striations on retrievals [3], this damage pattern remains widely unrecognized in retrieval and knee simulator studies, with the mechanism poorly understood. The higher contribution of pitting to total wear volume in revision-retrieved TKR suggests that the fatigue wear mechanism leading to pitting contributes to the need for the early revision of the implant

Introduction. Metal-on-metal (MOM) total hip arthroplasty using large diameter femoral heads offer clinical advantages however the failure rates of these hips is unacceptably high. Retrieved hips have a wide range of wear rates of their bearing and taper surfaces and there is no agreement regarding the cause of failure. Detailed visual inspection is the first step in the forensic examination of failed hip components and may help explain the mechanisms of failure. The aim of this study was to determine if there was a correlation between the results of detailed inspections and the volumetric wear of the bearing and taper surfaces of retrieved hips. Method. Detailed, non-destructive macroscopic and stereomicroscopic examinations of 89 retrieved MOM hip components were performed by a single experienced examiner using quantitative assessment to document the severity of 10 established damage features:. Light scratches, Moderate scratches, Heavy scratches, Embedded particles, Discolouration, Haziness, Pitting, Visible wear zone, Corrosion, Fretting. Each surface was considered in terms of zones comprising of quadrants (cup, head, and taper) and subquadrants (cup and head), Figure 1. Each zone was scored on a scale of 0 to 3 by determining the percentage of the surface area of the zone that exhibited the feature in question: a score of 0=0%, 1<25%, 25%<2<75%, 3>75%. The sum of the scores of each zone was used for the assessment of each damage feature. The volume of wear at the surfaces of each hip was measured with a Zeiss Prismo coordinate measuring machine (cup and head) and a Talyrond 365 roundness measurement instrument (taper), using previously reported methods. 1, 2. . Simple linear regression models were used to asses the univariable associations between the inspection scores and wear volumes. Multiple linear regression models were subsequently used to asses the simultaneous contribution of the inspection scores, found significant in univariable analyses, on the wear outcome variables. All statistical analysis was performed using Stata/IC version 12.1 (StataCorp, USA) and throughout a p value < 0.05 was considered statistically significant. Results. Visible wear zone, moderate scratches, discolouration and haziness scores were all significantly positively correlated with cup (R. 2. = 70%, 23%, 72% and 33% respectively) and head (R. 2. = 73%, 34%, 67% and 47% respectively) wear volumes. Visible wear zone and discoloration scores were significant predictors in multivariable analysis (p < 0.01) for both surfaces, together explaining 77% and 79% of the variance in the cup and head wear volumes respectively. Corrosion and discoloration scores were significantly positively correlated with taper wear volume (R. 2. = 57% and 53% respectively) and there was a significant interaction between the two damage features (p = 0.01). Discussion. This study demonstrates the importance of detailed visual inspections in retrieval analysis, suggesting that they may help in predicting the severity of bearing and taper surface wear. Future studies will involve assessments of the inter-observer errors of inspections and their relationship with many other variables such as implant design and patient factors

Introduction

Wear of the ultra-high molecular weight polyethylene (UHWMPE) component and the subsequent aseptic loosening remains a primary reason for late revision of total knee replacements (TKRs).[1] While improved measurement techniques have provided more quantitative information on the wear of surgically retrieved inserts, it is not well understood how observed damage patterns translate to volume loss of polyethylene in vivo. The overall purpose of this study is to investigate the relationship of damage patterns and volume loss at the articular surface of total knee replacements. We hypothesize that damage patterns are reliable predictors of volume loss.

Introduction

Failure of total knee replacements due to the generation of polyethylene wear debris remains a crucial issue in orthopedics. Unlike the hip, it is difficult to accurately determine knee implant wear rates from retrieved components. Several studies have relied on thickness measurements to estimate penetration, but the complicated geometry of contemporary tibial liners poses a challenge to accurately assess wear. In this study we address the question whether linear penetration can serve as a surrogate measure for volumetric material loss.

In the retrieval analysis of explanted hip joints, the estimation of wear volume and visualization of wear pattern are commonly used to evaluate in-vivo performance. While many studies report wear volumes from explanted hips, it is important to understand the limitations of these estimates including the sources and magnitude of uncertainty of the reported results. This study builds on a previous uncertainty analysis by Carmignato et al. to quantify the magnitude of uncertainty caused by the assumption that the as-manufactured shape of an explanted hip component is a perfect sphere.

Synthetic data sets representing idealized measurements of spheroidal explants (prolate, oblate and pinched) with a nominal diameter of 50 mm were generated. These data sets represent the shape and magnitude of form deviations observed for explanted hip components (Figure 1). Data were simulated for either unworn components or those with a known volume and magnitude of wear simulated to represent 5 µm penetration of a 49.90 mm femoral head into an acetabular cup (Table 1). The volume of wear and wear pattern were estimated using a custom Matlab script developed for analysis of metrology data from explanted hip joints. This script fits a least squares sphere to data points in unworn, as manufactured regions of the surface to estimate the as-manufactured shape of the component. The diameter of the best fit sphere, and wear volume were compared to the known wear depths and volumes from the synthetic datasets.

The results showed that the Matlab script estimated a wear volume of up to 1.4 mm³ for an unworn cup with a radial deviation of 10 µm. The maximum error of 13.3 mm³ was for a pinched cup with wear at the pole. The complete results are shown in Table 2.

In some cases with aspherical form deviations, the least squares sphere fitted to the synthetic data was displaced in the Z direction with respect to the origin of the spheroid and the radius of the least squares sphere was outside the range of the principal radii of the spheroid. For instance, in case 5, the center was shifted 22 µm vertically from the mathematical center.

The results from this study show that the magnitude of uncertainty due to form deviations on wear volume varies depending on the shape and magnitude of the form deviations and in some cases was greater than 10 mm³. A further important finding is that in some instances, the diameter and center of the least squares sphere fitted to the unworn regions may not be consistent with the mathematical radius and center of the synthetic data. This may have important implications for the “reverse engineering” of the as-manufactured dimensions from worn explanted hip joints.

Please contact authors directly for the figure:

Figure 1 Graphical depiction of a) synthetic data set, b) deviation map of a hemispherical acetabular cup with simulated wear, c) deviation map of a prolate spheroid with simulated wear at rim with color bar set to ±5 microns, d) deviation map of pinched ellipsoid with simulated wear at 45 degrees from pole.

With the introduction of highly crosslinked polyethylene (HXLPE) in total hip arthroplasty (THA), orthopaedic surgeons have moved towards using larger femoral heads at the cost of thinner liners to decrease the risk of instability. Several short and mid-term studies have shown minimal liner wear with the use HXLPE liners, but the safety of using thinner HXPLE liners to maximize femoral head size remains uncertain and concerns that this may lead to premature failure exist. Our objective was to analyze the outcomes for primary THA done with HXLPE liners in patients who have a 36-mm head or larger and a cup of 52-mm or smaller, with a minimum of 10-year follow-up. Additionally, linear and volumetric wear rates of the HXLPE were evaluated in those with a minimum of seven-year follow-up. We hypothesized that there would be minimal wear and good clinical outcome. Between 2000 and 2010, we retrospectively identified 55 patients that underwent a primary THA performed in a high-volume single tertiary referral center using HXLPE liners with 36-mm or larger heads in cups with an outer diameter of or 52-mm or smaller. Patient characteristics, implant details including liner thickness, death, complications, and all cause revisions were recorded. Patients that had a minimum radiographic follow-up of seven years were assessed radiographically for linear and volumetric wear. Wear was calculated using ROMAN, a validated open-source software by two independent researchers on anteroposterior X-rays of the pelvis. A total of 55 patients were identified and included, with a mean age of 74.8 (range 38.67 - 95.9) years and a mean BMI of 28.98 (range 18.87 - 63-68). Fifty-one (94.4%) of patients were female. Twenty-six (47.7%) patients died during the follow-up period. Three patients were revised, none for liner wear, fracture or dissociation. Twenty-two patients had a radiographic follow-up of minimum seven years (mean 9.9 years, min-max 7.5 –13.7) and were included in the long-term radiographic analysis. Liner thickness was 5.5 mm at 45 degrees in all cases but one, who had a liner thickness of 4.7mm, and all patients had a cobalt-chrome head. Cup sizes were 52mm (n=15, 68%) and 50mm (n=7, 32%). Mean linear liner wear was 0.0470 mm/year (range 0 - 0.2628 mm) and mean volumetric wear was 127.69 mm3/year (range 0 - 721.23 mm3/year). Using HXLPE liners with 36-mm heads or bigger in 52-mm cups or smaller is safe, with low rates of linear and volumetric wear in the mid to long-term follow-up. Patients did not require revision surgery for liner complications, including liner fracture, dissociation, or wear. Our results suggest that the advantages of using larger heads should outweigh the potential risks of using thin HXLPE liners

Total knee arthroplasty with a rotating hinge knee with carbon-fibre-reinforced (CFR)-PEEK as an alternative bushing material with enhanced creep, wear and fatigue behaviour has been clinically established [1-4]. The objective of our study was to compare results from in vitro biotribological characterisation to ex vivo findings on a retrievals. A modified in vitro wear simulation based on ISO 14243-1 was performed for 5 million cycles on rotating hinge knee (RHK) designs (EnduRo®) out of cobalt-chromium and ZrN-multilayer ceramic coating. The rotational & flexion axles-bushings and the flanges are made of CFR-PEEK with 30% polyacrylonitrile fibre content. Analysis of 12 retrieved EnduRo® RHK systems in cobalt-chromium and ZrN-multilayer in regard to loosening torques, microscopic surface analysis, distinction between different wear modes and classification with a modified HOOD-score has been performed. For the RHK design with the polyethylene gliding surface and bushings and flanges made out of CFR-PEEK, a cumulative volumetric wear was measured to be 12.9±3.95 mm. 3. in articulation to cobalt-chromium and 1.3±0.21 mm. 3. to ZrN-multilayer coating - a significant 9.9-fold decrease (p=0.0072). For the CFR-PEEK flexion bushing and flanges the volumetric wear rates were 2.3±0.48 mm. 3. /million cycles (cobalt-chromium) and 0.21±0.02 mm. 3. /million cycles (ZrN-multilayer) (p=0.0016). The 5 million cycles of in vitro wear testing reflect a mean in vivo service life of 2.9 years, which is in accordance to the time in vivo of 12–60 months of the retrieved RHK components [5]. The main wear modes were comparable between retrievals and in vitro specimens, whereby the size of affected area on the retrieved components showed a higher variation. For the EnduRo® RHK design the findings on retrieved implants demonstrate the high suitability of CFR-PEEK as a biomaterial for highly loaded bearings, such as RHK bushings and flanges in articulation to cobalt-chromium and to a ZrN-multilayer coating

Introduction. Fretting corrosion of the modular taper junction in total hip arthroplasty has been studied in several finite element (FE) studies. Manufacturing tolerances can result in a mismatch between the femoral head and stem, which can influence the taper mechanics leading to possibly more wear. Using FE models the effect of these manufacturing tolerances on the amount of volumetric wear can be studied. The removal of material in the FE model was validated against experiments simulating the clinical fretting wear process, subsequently the mismatch and assembly force were varied to study the effect on the volumetric wear. Methods. An FE model was developed in which the geometry can be updated to account for material removal due to wear. In this model the geometry was updated based on Archard's Law, using contact pressures, micromotions and a wear factor, which was determined based on accelerated fretting experiments. The linear wear was calculated using H=k*p*S. Where H is the linear wear depth in mm, k is a wear factor (mm. 3. /Nmm), p is the contact pressure (MPa) and S is the sliding distance (mm). 10 million cycles were simulated using 50 virtual steps. Using this scaling and the measured volumetric wear from the experiments a wear factor of 2.7*10. −5. was applied. Based on general manufacturing tolerances the resulting mismatch in taper angles were determined to be ± 1.26°. Using this mismatch a tip fit (figure 1a) and base fit (Figure 1b) model were created. In combination with a perfect fit, meaning no mismatch, and two different assembly forces of 4 kN and 15 kN, 6 different situations were studied. Results. No mismatch proved to result in the least amount of wear after 10 million simulated cycles (Figure 2). Assembling with 15 kN instead of 4 kN reduced the total volumetric wear and the volumetric wear rate. A base fit mismatch resulted in less volumetric wear than a tip fit mismatch. The 15 kN assembled mismatch cases showed a large initial amount of material removal after which the wear rate was lower than the 4 kN assembled cases. Discussion and conclusion. The results show that a perfect fit between the head and stem results in the least amount of wear. Furthermore a larger assembly force of 15 kN resulted in less wear than a 4 kN assembly force. The tip fit mismatch showed up to 144% more wear than the perfect fit where the base fit only had an increase in volumetric wear of 12%. The relative large tolerances in this study may overestimate actual mismatch, but give good insight into the effect that manufacturing tolerances can have on the taper mechanics and volumetric wear. Since manufacturing a perfect fit is impossible it is important to use a sufficiently high assembly force, when clinically possible, in order to reduce the amount of wear and wear rate significantly. For any figures or tables, please contact the authors directly

Highly crosslinked polyethylene (XLPE) was introduced to decrease peri-prosthetic osteolysis related to polyethylene wear, a major reason for revision of total hip arthroplasty. There are few reports of wear and osteolysis at 10 years post-operatively. We asked the following questions: (1) What are the linear and volumetric wear rates of one remelted XLPE at 10–14 years using the Martell method? (2) What is the relationship between volumetric wear, femoral head size, and osteolysis? (3) What is the incidence of osteolysis using conventional radiographs with Judet views and the Martell method?. Methods We evaluated a previously reported cohort of 84 hips (72 patients) with one design of an uncemented acetabular component and one electron-beam irradiated, remelted XLPE at a mean follow-up of 11 years (range 10 to 14 years). Measurements of linear and volumetric wear were performed in one experienced laboratory by the Martell method and standard radiographs, with additional Judet views, were used to detect peri-prosthetic osteolysis. Statistical analysis of wear and osteolysis compared to head size was performed. Results The mean linear wear rate by the first-to-last method was 0.024 mm/year (median, 0.010 mm/year) and the mean volumetric wear rate by this method was 12.2 mm. 3. /year (median, 3.6 mm. 3. /year). We found no association between femoral head size and linear wear rate. However, there was a significant relationship between femoral head size and volumetric wear rates, with 36/40 mm femoral heads having significantly higher volumetric wear (p=0.02). Small osteolytic lesions were noted in 12 hips (14%), but there was no association with head size, acetabular component position, or linear or volumetric wear rates. Conclusion This uncemented acetabular component and this particular remelted XLPE had low rates of linear and volumetric wear. Small osteolytic lesions were noted at 10 to 14 years, but were not related to femoral head size, linear or volumetric wear rates

Background. Aseptic loosening is the leading cause of total knee arthroplasty (TKA) failure in the long term, of which osteolysis from polyethylene wear debris remains a problem that can limit the lifetime of TKA past the second decade. To help speed up design innovations, our goal was to develop a computational framework that could efficiently predict the effect of many sources of variability on TKA wear—including design, surgical, and patient variability. Methods. We developed a computational framework for predicting TKA contact mechanics and wear. The framework accepts multiple forms of input data: patient-specific, population-specific, or standardized motions and forces. CAD models are used to create the FEA mesh. An analytical wear model, calibrated from materials testing (wheel-on-flat) experiments, is fully integrated into the FEA process. Isight execution engine runs a design of experiments (DOE) analysis with an outcome variable, such as volumetric wear, to guide statistical model output. We report two DOE applications to test the utility of the computational framework for performing large variable studies in an efficient manner: one to test the sensitivity of TKA wear to the femoral center of rotation, and the second to test the sensitivity of TKA wear to gait input perturbations. Results. Using this method, we demonstrated that choice of femoral center of rotation matters, and that although volumetric wear was most sensitive to variation in flexion/extension peaks, no one kinematic factor dominates TKA volumetric wear variability. Conclusion. The two DOE applications represent initial first attempts to study variability in component alignment and input waveforms across large solution spaces. The computational framework will be most useful if it can be used in a TKA design setting, where new innovations can be tested as soon as they are developed to see if they are worthy of further mechanical testing

Introduction. Subluxation and dislocation are frequently cited reasons for THA revision. For patients who cannot accommodate a larger femoral head, an offset liner may enhance stability. However, this change in biomechanics may impact the mechanical performance of the bearing surface. To our knowledge, no studies have compared wear rates of offset and neutral liners. Herein we radiographically compare the in-vivo wear performance of 0mm and 4mm offset acetabular liners. Methods. Two cohorts of 40 individuals (0mm, 4mm offset highly crosslinked acetabular liners, respectively) were selected from a single surgeon's consecutive caseload. All patients received the same THA system via the posterior approach. AP radiographs were taken at 6-week (‘pre’) and 5-year (‘post’) postoperative appointments. Patients with poor radiograph quality were excluded (n. 0mm. =5, n. 4mm. =4). Linear and volumetric wear were quantified according to Patent US5610966A. Briefly, images were processed in computer aided design (CAD) software. Differences in vector length between the center of the femoral head and the acetabular cup (pre- and post-vector, Figure 1) allow for calculation of linear wear and wear rate. The angle (β) between the linear wear vector and the cup inclination line was quantified (Figure 1). Patients with negative β were excluded from volumetric analyses (n. 0mm. =11, n. 4mm. =7). Volumetric wear was accordingly calculated accounting for wear vector direction. The results from three randomly selected patients were compared to results achieved using the “Hip Analysis Suite” software package (UChicagoTech). Results. Linear wear rate (Figure 2A) for 0mm offsets was significantly lower than the 4mm offsets (0.011±0.091 vs. 0.080±0.122mm/yr, p=0.008). Volumetric wear rate (Figure 2B) for 0mm offsets was significantly lower than the 4mm offsets (30.37±20.45 versus 61.58±42.14mm. 3. /year, p=0.001). Demographic differences existed between the two cohorts (age, gender, femoral head size, and acetabular cup size). However, there were no significant correlations found between linear/volumetric wear rate and any demographic including age, gender, BMI, femoral head size, or acetabular cup size. Validation showed no significant differences between the CAD method used herein and the gold standard method (0.083±0.014 versus 0.093±0.041mm/year, p=0.71). Discussion. This study is the first to show that 0mm offset liners have significantly lower linear and volumetric wear rates than do 4mm offset liners. Despite this difference, no revisions have been required in either cohort. The linear wear rates computed in this study are below literature-reported clinically relevant values for wear-induced-osteolysis (∼0.10mm/year). As such, the clinical impact of this wear rate difference is unknown. The higher wear rate in the offset group may owe to the altered biomechanics of the construct. By lateralizing the femoral head through an offset liner, the femur is lateralized with respect to the patient's center of mass (COM) (Figure 3). To maintain stability, the patient must pull the COM over the femoral head by increasing force from the hip abductors. This increased force is transmitted through the polyethylene acetabular liner. Thus, increased wear may result from the forces required to maintain balance in gait. Further work is needed to determine whether these higher wear rates will have clinical sequelae

Multi-directional motion at the ball-socket interface of a hip replacement joint has been discovered as a fundamental feature that determines the magnitude of wear for ultra-high molecular weight polyethylene (UHMWPE). The present study considers the wear of UHMWPE moving along a circular path with a uniform angular change rate of the velocity vector defined by the curvature of the sliding circle. It is apparent the as the sliding circle radius increases the motion is approaching more towards linear tracking. Therefore, wear rate per unit sliding distance would decrease with increasing the slidng circle radius. However, the sliding distance per cycle increases linearly with the radius of the circle, which would cause a proportional increase in the wear rate per cycle. We hypothesize that these two opposing effects on wear with respect to the changing radius of the sliding circle would cancel out each other leading to wear rate per cycle being independent of sliding distance. Experiments were conducted on a hip simulator with a biaxial rocking motion that results in a circular sliding path at the polar region of the acetabular cup that experiences the highest contact stresses and wear. The radius of the sliding circle, r, depends solely on the radius of the femoral ball, R, and the biaxial rocking angle, a, such that r=Rsina. Two tests were conducted. The first test was run under standard conditions with a constant biaxial rocking angle of +/−23 and head diameters ranging between 28 mm and 44 mm. Acetabular components were machined from virgin non-crosslinked UHMWPE with inner diameters matching those of the femoral heads. For the 28 mm bearing, the cups were of standard hemispherical geometry. The larger cups were truncated by various degrees so that the nominal contact area remained exactly the same as that of the standard 28 mm hemispherical components. The second test was run with the standard 28 mm components and various biaxial rocking angles: +/−10, +/−15, +/−20 and +/−23. Both tests were run for a total duration of 2 million cycles with diluted alpha-serum as a lubricant and physiologic loading (peak load: 2450N) as described by Paul. Volumetric wear at 2 million cycles for both tests are summarized in Figure 1. Fig. 2 shows a graphic representation of the total volumetric wear (DV) as a function of the sliding circle radius (r). Total volumetric wear is independent of the head diameter (2R), the biaxial-rocking angle (a) and the sliding circle radius (r). The total volumetric wear is proportional to the number of cycles and independent of the sliding distance per cycle. The clinically observed wear rate-ball diameter relationship, therefore, is not attributed to variations in sliding distance per walking step with differing ball head sizes. For the same nominal contact area between a ball and a socket, the total volumetric wear of UHMWPE is independent of the ball diameter, the biaxial rocking angle and the sliding circle radius. In other words, the total volumetric wear is proportional to the number of cycles and independent of the sliding distance per cycle

Introduction. Fretting corrosion at the taper interface of modular connections can be studied using Finite Element (FE) analyses. However, the loading conditions in FE studies are often simplified, or based on generic activity patterns. Using musculoskeletal modeling, subject-specific muscle and joint forces can be calculated, which can then be applied to a FE model for wear predictions. The objective of the current study was to investigate the effect of incorporating more detailed activity patterns on fretting simulations of modular connections. Methods. Using a six-camera motion capture system, synchronized force plates, and 45 optical markers placed on 6 different subjects, data was recorded for three different activities: walking at a comfortable speed, chair rise, and stair climbing. Musculoskeletal models, using the Twente Lower Extremity Model 2.0 implemented in the AnyBody modeling System™ (AnyBody Technology A/S, Aalborg, Denmark; figure1), were used to determine the hip joint forces. Hip forces for the subject with the lowest and highest peak force, as well as averaged hip forces were then applied to an FE model of a modular taper connection (Biomet Type-1 taper with a Ti6Al4V Magnum +9 mm adaptor; Figure 2). During the FE simulations, the taper geometry was updated iteratively to account for material removal due to wear. The wear depth was calculated based on Archard's Law, using contact pressures, micromotions, and a wear factor, which was determined from accelerated fretting experiments. Results. The forces for the comfortable walking speed had the highest peak forces for the maximum peak subject, with a maximum peak force of 3644 N, followed by walking up stairs, with a similar maximum peak force of 3626 N. The chair rise had a lower maximum peak force of 2240 N (−38.5%). The simulated volumetric wear followed the trends seen in the peaks of the predicted hip joint forces, with the largest wear volumes predicted for a comfortable walking speed, followed by the stairs up activity and the chair rise (Figure 3). The subjects with the highest peak forces produced the most volumetric wear in all cases. However, the lowest peak subject had a higher volumetric wear for the stairs up case than the average subject. Discussion. This study explored the effect of subject-specific variations in hip joint loads on taper fretting. The results indicate that taper wear was predominantly affected by the magnitudes of the peak forces, rather than by the orientation of the force. A more comprehensive study, capturing the full spectrum of patient variability, can help identifying parameters that accelerate fretting corrosion. Such a study should also incorporate other sources of variability, including surgical factors such as implant orientation, sizing, and offset. These factors also affect hip joint forces, and can be evaluated in musculoskeletal models such as presented here

Objective. Clinical wear depends on several factors such as implant specific factors (material, design, and sterilization), surgical factors/techniques, and patient-specific factors (weights and activities). The load magnitude for wear testing in the standard protocols (i.e., 2 kN as per ASTM F1714 or 3 kN as per ISO 14243-3) represent an average patient weight and does not address the other “what-if”’ scenarios (i.e., wear vs. patient weights, activities, duration, etc.,). The results from in-vitro testing report the data in wear (mg) or wear rate (mg/Mc) and are only applicable to the parameters (i.e., loads, bearing diameter, thickness, etc.,) used for the testing and not suitable to the variations seen in clinical scenarios. Therefore, it is essential to present the wear summary that can normalize the parameters and which is relevant in both in-vitro and in-vivo conditions. The goal of the current study is an attempt to present wear as a parameter (i.e., wear factor that combines the wear test data and established- theoretical relationship) and is thus applicable in both in-vivo and in-vitro scenarios. Methods. Wear factor was first evaluated using actual wear testing conducted on metal on cross-linked polyethylene bearings along with well-established Dowson's wall bridge equation. As per Dowson-Wallbridge, volumetric wear is V=2.376·KNWR+C or K=V/(2.376·NWR) where V is the volumetric wear in mm. 3. , K is the wear factor in mm. 3. /Nmm, N is the number of cycles, W is the load in Newtons, R is the bearing radius in mm, and C is the creep (assumed to be negligible, i.e., C=0 in this model. 28 mm simulator wear was first used to evaluate wear factor, but since simulator wear presented as a mass loss, these results were converted to volumetric wear using the equation. V. =. m. /. ρ. ,. (m is the wear in mg and r is the density of XLPE in mg/mm. 3. (=0.923). The Dowson-Wallbridge equation was then validated for predictive accuracy against actual wear testing on the predecessor THR system. The wear factor thus obtained was used to compute the theoretical-wear for other sizes (i.e., 42 and 46 mm bearings). The theoretical-wear was then compared to simulator wear for predictive accuracy. Results & Discussion. Figure1 below shows the verification of the predictive capability of the Dowson-Wallbridge equation against historical wear data. The theoretical-wear (for 42 and 46 mm bearings) evaluated using wear factor was in good agreement with the simulator wear The results show Dowson's Wallbridge equation was verified and thus can be used to assess the wear factor. The results show that the wear factor for XLPE system is 1.79 × 10. −10. mm. 3. /N-mm. Elfick et al. evaluated the clinical wear factor for 47 retrieved acetabular components with varying diameters, patients, and liner thickness ranging from 1.8 mm (thinnest) to 11.0 mm thick liners using the Dowson-Wallbridge equation and reported the mean wear factor as 1.93 × 10. −9. mm. 3. /N-m. The results of the current evaluation are also in good agreement with clinical studies

Introduction. Metal-on-polyethylene (MoP) is the most commonly used bearing couple in total hip replacements (THRs). Retrieval studies (Cooper et al, 2012, JBJS, Lindgren et al, 2011, JBJS) report adverse reactions to metal debris (ARMD) due to debris produced from the taper-trunnion junction of the modular MoP THRs. A recent retrospective observational study (Matharu et al, 2016, BMC Musc Dis) showed that the risk of ARMD revision surgery is increasing in MoP THRs. To the authors' best knowledge, no hip simulator tests have investigated material loss from the taper-trunnion junction of contemporary MoP THRs. Methods. A 6-station anatomical hip joint simulator was used to investigate material loss at the articulating and taper-trunnion surfaces of 32mm diameter metal-on-cross-linked polyethylene (MoXLPE) joints for 5 million cycles (Mc) with a sixth joint serving as a dynamically loaded soak control. Commercially available cobalt-chromium-molybdenum (CoCrMo) femoral heads articulating against XLPE acetabular liners (7.5Mrad) were used with a diluted new-born-calf-serum lubricant. Each CoCrMo femoral head was mounted on a 12/14 titanium alloy trunnion. The test was stopped every 0.5Mc, components were cleaned and gravimetric measurements performed following ISO 14242-2 and the lubricant was changed. Weight loss (mg) obtained from gravimetric measurements was converted into volume loss (mm. 3. ) and wear rates were calculated from the slopes of the linear regression lines in the volumetric loss versus number of cycles plot for heads, liners and trunnions. Additionally, volumetric measurements of the head tapers were obtained using a coordinate measuring machine (CMM) post-test. The surface roughness (Sa) of all heads and liners was measured pre and post-test. At the end of the test, the femoral heads were cut and the roughness of the worn and unworn area was measured. Statistical analysis was performed using a paired-t-test (for roughness measurements) and an independent sample t-test (for wear rates). Results and Discussion. The mean volumetric wear rates for CoCrMo heads, XLPE liners and titanium trunnions were 0.019, 2.74 and 0.013 mm. 3. /Mc respectively. There was a statistically significant decrease (p<0.001) in the Sa of the liners post-test. This is in contrast to the femoral heads roughness in which no change was observed (p = 0.338). This head roughness result matches with a previous MoP in vitro test (Saikko, 2005, IMechE-H). The Sa of the head tapers on the worn area showed a statistically significant increase (p<0.001) compared with unworn, with an associated removal of the original machining marks. The mean volumetric wear rate of the head tapers obtained using the CMM (0.028 ± 0.016 mm. 3. /Mc) was not statistically different (p=0.435) to the mean volumetric wear rate obtained gravimetrically (0.019 ± 0.020 mm. 3. /Mc) for the femoral heads. Therefore, wear of the heads arose mainly from the internal taper. The mean wear rates of the CoCrMo taper and titanium trunnion are in agreement with a MoP explant study (Kocagoz et al, 2016, CORR). Conclusion. This is the first long-term hip simulator study to report wear generated from the taper-trunnion junction of MoP hips

Introduction. Surface wear of polyethylene is still considered a long-term risk factor for clinical success, particularly as life expectancy and activity levels increase. Computational models have been used extensively for preclinical wear prediction and optimization of total knee replacements (TKR). In most cases, the input wear parameters (wear factors and coefficients) to the computational models have been experimentally measured under average contact stresses to simulate standard activities. These wear studies are not therefore applicable for more adverse conditions that could lead to edge loading and high stress conditions, including higher levels of activities and severe loading conditions. The current study investigated the multidirectional pin-on-plate wear performance of moderately cross-linked ultra-high molecular weight polyethylene (UHMWPE) under high applied nominal contact stress, to be used as inputs to a computational model investigating adverse high stress conditions. Materials/Methods. Moderately cross-linked UHMWPE (GUR_1020,5Mrad gamma irradiation) pins were tested against cobalt–chrome alloy (CoCr) plates in a multidirectional pin-on-plate wear simulator. The CoCr metallic plates were polished to an average surface roughness of 0.01μm. The pin rotation and the plate reciprocation of ±30º and 28mm were in phase, having a common frequency of 1Hz, and resulted in a multidirectional motion at the pin-plate contact surface in a flat-on-flat configuration. Six different pin diameter and applied load combinations were tested, resulting in applied nominal contact stresses from 4 to 80[MPa](Fig.1). Each set was run for 1million cycles in 25% bovine serum as a lubricant. The volumetric wear was calculated from the weight loss measurements using a density 0.93mg/mm. 3. for the UHMWPE material. The wear factor and wear coefficient were calculated as (volumetric wear/(load x sliding distance)) and (volumetric wear/(contact area x sliding distance)) respectively[1]. Statistical analysis of the data was performed in ANOVA and significance was taken at p<0.05. Results. Changing the load from 80 to 216[N] (5mm_pins) and from 212 to 283[N] (3mm_pins), increased the volumetric wear from 1.38±0.12 to 1.66±0.07 and from 0.8±0.12 to 1.03±0.05[mm. 3. ] respectively (mean±95% confidence interval (CI), n=6). However, under the same load of 216N, changing the pin diameter from 5 to 3 [mm] decreased the volumetric wear from 1.66±0.07 to 0.86±0.02[mm. 3. ] (mean±95% CI, n=6) (Fig.1). For stress levels from 4 to 30[MPa] the wear factor significantly decreased from 3.06±0.27 to 0.67±0.11×10. −7. mm. 3. /N.m] (mean±95%CI, n=6, p<0.001). Any further increase in the stress level (up to 80MPa) did not affect the measured wear factor (ANOVA, p=0.44) (Fig.2-a). In contrast, the measured wear coefficient increased from 1.25±0.11 to 4.88±0.14×10. −9. ] (mean±95% CI, n=6, p<0.001) while increasing the stress from 4 to 80[MPa](Fig.2-b). Discussion. For the same level of motion at the contact surfaces, the two main parameters that significantly contributed to the volumetric wear were the applied load and contact area. The measured wear parameters were significantly dependent on the applied nominal contact stress. Future work will consider different motions at the contact surfaces with different degrees of cross-shear. Conclusion. The stress level significantly affected the wear performance of moderately cross-linked UHMWPE in this pin-on-plate configuration. Computational simulations of TKR should therefore account for these effects when considering adverse high stress conditions

The purpose of this investigation is to assess the rate of wear the effect once the “bedding in period”/ poly creep had been eliminated. Creep is the visco-elastic deformation that polyethylene exhibits in the first 6–12 weeks. We also assessed the wear pattern of four different bearing couples in total hip arthroplasty (THA): cobalt-chrome (CoCr) versus oxidized zirconium (OxZir) femoral heads with ultra-high molecular weight polyethylene (UHMWPE) versus highly-crosslinked polyethylene (XLPE) acetabular liners. This was a randomized control study involving 92 patients undergoing THA. They were randomized to one of four bearing couples: (1) CoCr/UHMWPE (n= 23), (2) OxZir/UHMWPE (n=21), (3) CoCr/XLPE (n=24), (4) OxZir/XLPE (n=24). Patients underwent a posterior approach from one of three surgeons involved in the study. All patients received a porous-coated cementless acetabular shell and a cylindrical proximally coated stem with 28 mm femoral heads. Each patient was reviewed clinically and radiographically at six weeks, three and 12 months, two, five and 10 years after surgery. Standardized anteroposterior and lateral radiographs were taken. All polyethylene wear was measured by an independent blinded reviewer. Linear and volumetric wear rates were measured on radiographs using a validated computer software (Polyware Rev. 5). Creep was defined as the wear at 6 or 12 weeks, depending on if there was a more than 10% difference between both measurements. If a greater than 10% difference occurred than the later period's wear would be defined as creep. 72 hips were included in analysis after exclusion of seven revisions, three deaths and 10 losses to follow-up. The annual linear wear rates (in mm/y) at 10 years were (1) 0.249, (2) 0.250, (3) 0.074 and (4) 0.050. After adjusting for creep these rates become were (1) 0.181, (2) 0.142, (3) 0.040 and (4) 0.023. There is statistical differences between raw and adjusted linear wear rates for all bearing couples. The percentage of the radiographically measured wear at 10 years due to creep is (1) 30% (2) 44%, (3) 58.5% and (4) 51.5% with significant differences in couples with XLPE versus those with UHMWPE. There was no significant correlation between age, gender, cup size, tilt, planar anteversion and the linear or volumetric wear rates. The linear wear rate of both UHMWPE and XLPE are even lower thxdsxzan previously described when creep is factored out. XLPE has again demonstrated far superior linear wear rates at 10 years than UHMWPE. There were no significant differences in wear rate at 10 years between CoCr and OxZir, this may be due to an underpowered study. XLPE exhibits proportionally more creep than UHMWPE within the first 6–12 weeks and accounts for more of the total wear at 10 years as measured radiographically at the end period

Introduction. The most common bearing couple used in total knee arthroplasty (TKA) is ultra-high molecular weight polyethylene (UHMWPE) articulating against a CoCrMo alloy femoral component. Although this couple has demonstrated good clinical results, UHMWPE wear has been identified as one of the principal causes for long-term failure of total knee joint replacements. 1. indicating a need for improvements in TKA bearings technology. The wear resistance of UHMWPE can be improved by radiation crosslinking; however, in order to get the full benefit of this improved wear resistance, an abrasion resistant ceramic counterface is necessary. 2. Since the radiation crosslinking degrades mechanical properties, it is also important to have an optimized radiation dose and subsequent processing. The purpose of this study was to evaluate the long-term wear performance of VERILAST Technology comprising two advanced bearing technologies, abrasion resistant OXINIUM femoral components (OxZr). 3-4. and wear/strength optimized 7.5 Mrad crosslinked polyethylene (7.5-XLPE). 5. Materials and Methods. Three component assemblies of LEGION(tm) cruciate retaining (CR) OxZr femoral components, 7.5-XLPE tibial inserts were tested on an AMTI knee simulator under displacement control at 1 Hz frequency as described previously. 2. The tibial inserts were manufactured from compression molded GUR 1020 UHMWPE, radiation crosslinked to 7.5 Mrad dose, remelted to extinguish free radicals, and sterilized by EtO. The wear test was conducted for 45 Mcycle, which was considered to be a conservative estimate for the amount of cycles that would occur during 30 years of typical in-vivo use based on the relationship between patient age and the number of loading cycles as reported in the literature. 6-8. Results. The predominant wear feature on the 7.5-XLPE inserts was burnishing. There were no signs of fatigue wear or delamination. The mean volumetric wear rate (± SD) of the 7.5-XLPE inserts articulating against OxZr femoral components for 45 Mcycle was 0.58±0.17 mm. 3. /Mcycle. In a previous wear test under substantially identical conditions for 5 Mcycle simulating approximately 3 years of use, the mean volumetric wear rate of CoCr and virgin UHMWPE (CPE) couples was 23.4±2.4 mm. 3. /Mcycle. 2. The mean volumetric wear rate of the OxZr/7.5-XLPE couples was approximately 98% lower compared to the CoCr/CPE couples (p<0.01). After simulating 3 years of use, the mean volumetric wear of OxZr/7.5-XLPE couples (2.67 mm. 3. ) was approximately 98% lower than CoCr/CPE couples (120.42 mm. 3. ) (Figure 1). Furthermore, after simulating 30 years of use, the mean volumetric wear of OxZr/7.5-XLPE couples (22.78mm. 3. ) was approximately 81% lower than the CoCr/CPE couples after simulating 3 years of use (120.42 mm. 3. ) (Figure 2). Discussion. This study demonstrates that coupling OxZr femoral components with 7.5-XLPE inserts results in a TKA bearing combination that provides and maintains significantly lower, long-term wear performance

Introduction. Despite the positive outcomes in shoulder joint replacements in the last two decades, polyethylene wear debris in metal-on-polyethylene artificial shoulder joints is well-known as a limitation in the long-term survival of shoulder arthroplasties systems. Consequently, there is an interest in the use of novel materials as an alternative to hard bearing surfaces such as pyrolytic carbon layer (PyroCarbon). Materials and Methods. In the present study, the unique Newcastle Shoulder Wear Simulator was used (Smith et al., 2015; Smith et al., 2016) to evaluate the wear behavior of four commercially available PyroCarbon humeral heads 43 mm diameter, articulating against conventional ultra-high molecular weight polyethylene (UHMWPE) glenoid inserts with a radius of curvature of 17.5 mm to form an anatomic total shoulder arthroplasty. A physiological combined cycled “Repeat-motion-load” (RML) (Ramirez-Martinez et al., 2019) obtained from the typical activities of daily life of patients with shoulder implants was applied as a simulator input. A fifth sample of the same size and design was used as a soak control and subjected to dynamic loading without motion during the wear test. The mean volumetric wear rate of PyroCarbon-on-polyethylene was evaluated over 5 million cycles gravimetrically and calculated on the basis of linear regression, as well as the change in surface roughness (S. a. ) of the components using a non-contacting white light profilometer throughout the test. Results. The gravimetric analysis showed a mean volumetric wear rate and standard deviation of 19.3±9.5 mm. 3. /million cycles for the UHMWPE glenoid inserts, whereas PyroCarbon humeral head counterparts did not exhibit a loss in mass throughout the test. The roughness values of the UHMWPE glenoid inserts decreased (P < .001), changing from 296±28 nm to 32±8 nm at the end of the test. In contrast, the PyroCarbon humeral heads did not show a significant change (P = .855) over the 5 million cycles; remained in the same range (21±2 nm to 20±10 nm) with no evidence of wear damage on the surface. Conclusions. This is the first in-vitro shoulder simulator study of a PyroCarbon on UHMWPE articulation. Wear rates were similar to that found to well-proven metal on UHMWPE shoulder arthroplasties. While it was interesting to see that the PyroCarbon did not roughen over the test duration, the lack of an appreciable reduction in wear of the UHMWPE component when articulated with an expensive and complex to manufacture PyroCarbon component likely means there is little clinical cost-benefit in the use of a PyroCarbon on UHMWPE shoulder implant. Declaration of competing interest. Prof. Ian A. Trail received some royalties and research support from Wright Medical Group N.V. None of the other authors, their immediate families, and any research foundation with which they are affiliated did not receive any financial payments or other benefits from any commercial entity related to the subject of this article. For any figures or tables, please contact authors directly

Background. Wear and osteolysis are major contributors, which limit the durability of total hip Arthroplasty (THA) and ultimately cause it to fail. Efforts were made to decrease wear by highly cross-linked polyethylene (HXLPE) and using ceramic bearings. Questions/Purposes. The purpose of this study is to analyze and compare the five year performance of large sized (32mm and 36mm) ceramic and metal heads on X3 HXLPE (Stryker, Mahwah, NJ, USA). Materials and Methods. One hundred and twenty near-consecutive patients that underwent primary THA between January 2006 and December 2009 for osteoarthritis with five-year radiographic and clinical follow-up were identified from our institutional review board-approved prospective database. All patients received a non-cemented THA with larger femoral head (32 or larger) on X3 HXLPE, either a ceramic (n=60) or metal (n=60). Linear and volumetric wear was measured using the computer-assisted Roman software. Results. At final follow up, the mean wear rates were not significantly different (p=0.63): 0.018 ± 0.06 mm/yr and 0.021 ± 0.06 mm/yr for ceramic-on-X3 and metal-on-X3, respectively. When negative values were considered zero as worst-case scenario, wear rates for ceramic-on-X3 and metal-on-X3 HXLPE groups were 0.032 ± 0.04 mm/yr and 0.041 ± 0.05 mm/yr, respectively (P=0.55). Mean volumetric wear rates were also statistically similar: 68.56 mm3/y and 79.96 mm3/y for the ceramic-on-X3 and metal-on-X3 HXLPE groups respectively (p=0.78); when negatives were considered zeroes, they were 121.42 mm3/y and 164.63 mm3/y, respectively (p=0.20). Patients with ceramic heads were significantly younger (p <0.01), more active (p<0.01) and had better clinical scores than those with metal heads. Conclusions. Large ceramic and metal heads on HXLPE have excellent durability at minimum 5 years followup without any statistical significant difference in linear or volumetric wear rates