There are many methods for analysing wear volume in failed polyethylene acetabular components. We compared a radiological technique with three recognised ex vivo methods of measurement.

We tested 18 ultra-high-molecular-weight polyethylene acetabular components revised for wear and aseptic loosening, of which 13 had pre-revision radiographs, from which the wear volume was calculated based upon the linear wear. We used a shadowgraph technique on silicone casts of all of the retrievals and a coordinate measuring method on the components directly. For these techniques, the wear vector was calculated for each component and the wear volume extrapolated using mathematical equations. The volumetric wear was also measured directly using a fluid-displacement method. The results of each technique were compared.

The series had high wear volumes (mean 1385 mm³; 730 to 1850) and high wear rates (mean 205 mm³/year; 92 to 363). There were wide variations in the measurements of wear volume between the radiological and the other techniques. Radiograph-derived wear volume correlated poorly with that of the fluid-displacement method, co-ordinate measuring method and shadowgraph methods, becoming less accurate as the wear increased. The mean overestimation in radiological wear volume was 47.7% of the fluid-displacement method wear volume.

Fluid-displacement method, coordinate measuring method and shadowgraph determinations of wear volume were all better than that of the radiograph-derived linear measurements since they took into account the direction of wear. However, only radiological techniques can be used in vivo and remain useful for monitoring linear wear in the clinical setting.

Interpretation of radiological measurements of acetabular wear must be done judiciously in the clinical setting. In vitro laboratory techniques, in particular the fluid-displacement method, remain the most accurate and reliable methods of assessing the wear of acetabular polyethylene.

Introduction. There is much current debate concerning wear and corrosion at the taper junctions of large head total hip replacements, particularly metal-on-metal hips. Is such damage a modern concern or has it always occurred in total hip replacement but not previously noted. To investigate this five explanted V40 Exeter femoral stems (Stryker Howmedica) were obtained following revision surgery at a single centre. In all cases, the 24–26 mm femoral heads were still attached. Hypothesis. In conventional ‘small head’ modular hip prostheses such as the Exeter, negligible wear and corrosion is seen at the taper junction of explanted devices. Methods. The articulating surface and the taper junction of each femoral heads was measured using a Mitutoyo LEGEX322 co-ordinate measuring machine (CMM) In each case a wear map was generated and the wear volume from the contact surface was calculated using a bespoke MATLAB program. The accuracy of such measurements has been previously shown to be within 0.5mm3. Results. Wear analysis of the articulating surfaces found unworn surfaces with each femoral head having less than 1 mm. 3. volumetric wear. All tapers had minimal wear with volumetric wear of less than 0.5 mm. 3. . Discussion and Conclusion. The wear volumes measured fall within the CMM measuring accuracy of 0.5mm. 3. Furthermore all tapers showed low wear volumes indicating that the taper junction had functioned correctly and distributed the load across the length of the truneon. Significance. This work adds to the growing evidence that taper problems in modern hip prostheses are associated with increasing head diameter and smaller taper dimensions

Introduction. Ten explanted pyrolytic carbon components of a number of finger prostheses were obtained at revision surgery for wear analysis. Implants were removed for either dislocation or failure of fixation. Hypothesis Failure of the components was due to wear from the articulating surfaces, as occurs in many hip and knee prostheses. Methods. The articulating surfaces were examined using a ZYGO NewView 5000 non-contact profilometer with a resolution of 1nm, to determine the roughness average (RA) of the surface. A total of 86 RA measurements were taken. Detailed images of the surface displayed as a 3D map of were acquired. The RA values for each component were averaged and compared against the British standard for orthopaedic implants, which states that the articulating surfaces of devices made of metal or ceramic should have RA values lower than 0.050 µm. Results. The low surface roughness demonstrated that the vast majority of the articulating surfaces of the components were relatively unworn with RA values lower than British standard, even following use in vivo. ZYGO images showed light unidirectional scratching on four of the explanted components, but despite the scratching, the RA values of these components were still low (<0.050 µm) showing that this was superficial damage. No other significant damage was observed. Discussion. Due to the lack of damage on the articulating surfaces and the low RA values recorded the failure of these prostheses is not considered to be wear related. Significance This is the first report of ex vivo analysis of pyrolytic carbon finger prostheses

This study reports the mid-term results of a large bearing hybrid metal on metal total hip replacement (MOMHTHR) in 199 hips (185 patients) with mean follow up of 62 months. Clinical, radiological outcome, metal ion levels and retrieval analysis were performed. Seventeen patients (8.6%) had undergone revision, and a further fourteen are awaiting surgery (defined in combination as failures). Twenty one (68%) failures were females. All revisions and ten (71%) of those awaiting revision were symptomatic. Twenty four failures (86%) showed progressive radiological changes. Fourteen revision cases showed evidence of adverse reactions to metal debris (ARMD). The failure cohort had significantly higher whole blood cobalt ion levels (p=0.001), but no significant difference in cup size (p=0.77), inclination (p=0.38) or cup version (p=0.12) in comparison to the non revised cohort. Female gender was associated with an increased risk of failure (chi squared p=0.04). Multifactorial analysis demonstrated isolated raised Co levels in the absence of either symptoms or XR changes was not predictive of failure (p=0.675). However both the presence of pain (p<0.001) and XR changes (p<0.001) in isolation were both significant predictors of failure. Wear analysis (n=5) demonstrated increased wear at the trunnion/head interface (mean out of roundness measurements of 34.5 microns +/−13.3 (+/−2SD, normal range 8-10 microns) with normal levels of wear at the articulating surfaces. There was evidence of corrosion at the proximal and distal stem surfaces. The cumulative survival rate, with revision for any reason was 92.4% (95%CI: 87.4-95.4) at 5 years. Including those awaiting surgery, the revision rate would be 15.1% with cumulative survival at 5 years of 89.6% (95% CI: 83.9-93.4). This MOMHTHR series has demonstrated unacceptable high failure rates with evidence of high wear at the head/trunnion interface and passive corrosion to the stem surface. This raises concern with the use of large heads on conventional 12/14 tapers. Female gender was an independent risk factor of failure. Metal ion levels remain a useful aspect of the investigation work up but in isolation are not predictive of failure

SUMMARY. The relationship between component position, wear rate and edge loading was investigated for 115 explanted current generation Metal-on-Metal (MoM) hips. Edge wear was detected in: 63% of all hips; and 48% of those with cups positioned within Lewinnek's box. BACKGROUND. The link between steeply inclined cups (>55 degrees) and edge loading is known for all common hip bearing couples. Edge loading is associated with high rates of wear, and has been linked to premature failure of hips. METHODS. The wear of failed hip joints was measured using a Taylor Hobson Talyrond 365. Edge loading was identified when the depth of the wear scar was maximum at the rim of the cup. The position of the cups was measured from plain radiographs or 3D CT. RESULTS. A total of 115 retrieved hips were available with position and wear analysis. The median age of patients was 58 years (25 – 87) and the median time before revision was 38 months (4 – 121). All hips were measured for inclination and 78 were measured for version. The median (range) of cup inclination was 51 degrees (15 – 82), and cup version was 18.5 degrees (-47 – 61). 63% of cups were found to be edge loaded. The median wear rate of the edge loaded cups was 12 μm per year compared to 1.88 μm per year for non-edge loaded cups. Edge loading was found in all components with an inclination steeper than 60°. Edge loading was found at inclination angles as low as 30°. 23 cups were placed within Lewinnek's safe zone: inclination of 40 ± 10degrees, and version of 15 ± 10 degrees. However, 11 of these “well positioned” components were edge loaded. Of the edge loaded components in Lewinnek's box, none had an inclination less than 40 degrees. CONCLUSIONS. Edge loading occurred at cup inclination angles lower than previously reported. It is believed that edge wear is related to the contact patch between head and cup, overlapping the edge of the cup, causing disruption to the lubrication regime and increased contact pressures at the edge of the cup. Work is progressing to calculate the size of contact patch for the explanted hips and position in the cup

INTRODUCTION. There is increasing worldwide interest in the assessment of wear in explanted hip components. This is due is part to high profile failures of orthopaedic components in the US, whilst in the UK hip resurfacings have been experiencing a higher than expected failure rate. The reasons for these failures are not well understood, with data from the NJR suggesting the 43% of MoM resurfacing failures are unexplained. Wear analysis is a vital tool in determining failure mechanisms and ultimately improving the longevity of joint replacements through improved design and manufacturing control. There are currently no relevant measurement standards for the evaluation of retrieved orthopaedic components. This paper will assess two of the most commonly used techniques namely roundness measurement and co-ordinate measurement. The advantages and disadvantages of both techniques are considered in this paper. ROUNDNESS MACHINE. The Talyrond 365 is a stylus based roundness machine. The component is located on a rotating table and the stylus measures the deviation from a perfect circle as the component is slowly rotated. The Talyrond measures a single profile to an accuracy of 30 nm and up to 72,000 data points per revolution. The air spindle has a radial accuracy of <0.02 μm and the Talymin gauge a minimum resolution of 12 nm. Individual roundness profiles can be stitched together to build up 3D cylinder maps, allowing 3D pictures of sections of explanted hip components to be generated. COORDINATE MEASURING MACHINE. Co-ordinate measuring machines (CMMs) have been widely used in manufacturing quality and research departments for a number of years and the CMM is recognised as a powerful and important tool capable of ascertaining geometric data from a component. The CMM used in this study was a Zeiss Prismo CMM (Carl Zeiss Ltd., Rugby, UK) with a probing error of 0.7 μm. Components are securely held in a chuck fixture arrangement and the dimensions of the component in the portion of the bearing that is unworn is ascertained through measurement. The initial measurements are used to produce a reverse engineered 3D CAD surface which represents the component ‘pre-wear’ surface. The surface of the component is then scanned and the deviation from this pre-wear surface is mapped. The maximum linear wear and wear volume are then calculated directly. DISCUSSION. The main advantage of CMM and Talyrond is that they are available in most metrology and measurement rooms. The CMM is a particularly versatile machine and can be used to measure any orthopaedic components. There is a need to develop a suitable Standard for both machines detailing a protocol to measure explanted hip and quantify the wear. A study is underway to measure a set of explanted hip components to allow a detailed comparison between of measurements between the Talyrond and CMM. The result of this study will be included in the paper. CONCLUSIONS. The CMM and Talyrond are both instruments suited to measuring wear of explanted hips. A full evaluation of the systems and the development of robust measurement protocol and standard would be advantageous to the orthopaedic industry

Introduction. The biological response to UHMWPE particles generated by total joint replacements is one of the key causes of osteolysis, which leads to late failure of implants. Particles ranging from 0.1-1.0μm have been shown to be the most biologically active, in terms of osteolytic cytokine release from macrophages [1]. Current designs of lumbar total disc replacements (TDR) contain UHMWPE as a bearing surface and the first reports of osteolysis around TDR in vivo have appeared recently in the literature [2]. The current wear testing standard (ISO18192-1) for TDR specifies only four degrees of freedom (4DOF), i.e. axial load, flexion-extension, lateral bend and axial rotation. However, Callaghan et al. [3] described a fifth DOF, anterior-posterior (AP) shear. The aim of this study was to investigate the effect that this additional AP shear load component had on the size and morphology of the wear particles generated by ProDisc-L TDR devices over five million cycles in a spine simulator. Methods. A six-station lumbar spine simulator (Simulation Solutions, UK) was used to test ProDisc-L TDR components (Synthes Spine, USA) under the ISO 18192-1 standard inputs and with the addition of an AP load of +175 and −140N. Wear particles were isolated at 2 and 5 mc using a modified alkaline digestion protocol [4]. Particles were collected by filtration and imaged by high resolution FEGSEM. Particle number and volume distributions were calculated as described previously [4] and were compared statistically by one way ANOVA (p<0.05). Results. Similar particle morphologies were observed under 4DOF and 5DOF inputs, including flakes, fibrils and granules. No significant differences were observed between the size and volume distributions under 4DOF and 5DOF when comparisons were made at the same time point, although there was a trend towards larger particles being generated under 5DOF inputs. The mode of the frequency distribution was in the submicron size range with the volume distributions showing greater variability. Discussion. This study represents the first comprehensive wear particle analysis comparing 4DOF (ISO conditions) to 5DOF inputs on a single TDR device. Vicars et al. [5] reported no significant differences in the wear volume of ProDisc-L TDR components under 4 and 5DOF inputs. The present study has shown that the particle size distributions and particle morphologies were not significantly affected by the addition of AP shear. The wear particles were similar in size and morphology to those previously reported for total hip replacements and total knee replacements [6], indicating that wear debris produced by TDR may have a similar potential for osteolysis

Objectives

Third-body wear is believed to be one trigger for adverse results with metal-on-metal (MOM) bearings. Impingement and subluxation may release metal particles from MOM replacements. We therefore challenged MOM bearings with relevant debris types of cobalt–chrome alloy (CoCr), titanium alloy (Ti6Al4V) and polymethylmethacrylate bone cement (PMMA).