Objectives. Modular dual-mobility (MDM) constructs are used to reduce dislocation rates after total hip replacement (THR). They combine the advantages of dual mobility with the option of supplementary acetabular screw fixation in complex revision surgery. However, there are concerns about adverse reaction to metal debris (ARMD) as a result of fretting corrosion between the metal liner and shell. Methods: The aim of this systematic review was to find and review all relevant studies to establish the outcomes and risks associated with MDM hip replacement. All articles on MDM THRs in the Medline, EMBASE, CINAHL, Cochrane Library, and Prospero databases were searched. A total of 14 articles were included. A random intercept logistic regression model was used for meta-analysis, giving estimated average values. Results: There were 6 cases of ARMD out of 1312 total. Estimated median incidence of ARMD from meta-analysis was 0.3% (95% CI 0.1 – 1.4%). Mean postoperative serum Cobalt was 0.81 μg/L (95% CI 0.33 – 1.29 μg/L), and Chromium was 0.77 μg/L (95% 0.35 – 1.19 μg/L), from 279 cases in 7 studies. Estimated median incidence of a serum cobalt or chromium ion measurement ≥1 μg/L was 7.9% (95% CI 3.5 – 16.8%), and ≥7 μg/L was 1.8% (95% CI 0.7 – 4.2%). Conclusions: ARMD is a rare but significant complication following total hip replacement using a MDM construct. Its incidence appears higher than that reported in non-metal-on-metal (MoM) hip replacements but lower than that of MoM hip replacements. MDM hip replacements are associated with raised serum metal ion levels postoperatively, but there was no correlation with worse clinical hip function within studies. Studies were poor quality and at high risk of confounding. Pending further work, MDM constructs should be used with caution, reserved for select cases at particularly high risk of dislocation

Introduction. In THA, fretting corrosion at the head-stem taper junction has emerged as a clinical concern that may result in adverse local tissue reactions, even in patients with a metal-on-polyethylene bearing [1]. Taper junctions that employ a ceramic head have demonstrated reduced corrosion at the interface [2]. However, during revision surgery with a well-fixed stem, a titanium sleeve is used in conjunction with a ceramic head to ensure proper fit of the head onto the stem and better stress distribution. In vitro testing has suggested that corrosion is not a concern in sleeved ceramic heads [3]; however, little is known about the in vivo fretting corrosion of the sleeves. The purpose of this study was to investigate fretting corrosion in sleeved ceramic heads. Materials and Methods. Between 2001 and 2014, 35 sleeved ceramic heads were collected during revision surgery as part of a multi-center retrieval program. The sleeves were all fabricated from titanium alloy and manufactured by 4 companies (CeramTec (n=14), Smith & Nephew (Richards, n=11), Stryker (n=5), and Zimmer (n=5)). The femoral heads were made from 3 ceramics (Alumina (n=7), Zirconia (n=11), and Zirconia-toughened Alumina (n=17)). Sleeve dimensions (length and thickness) were measured using calibrated calipers. Fretting corrosion of the sleeves and available associated stems was scored using a 4-point, semi-quantitative scoring system [4], with 1 being little-to-no damage, and 4 corresponded to severe fretting corrosion. Five sleeves could not be extracted; thus the external surface was not scored. Results. Moderate-to-severe fretting corrosion scores (Score ≥ 2) were observed in 97% (34/35) of internal tapers (sleeve-femoral stem contact), 57% (17/30) of external tapers (sleeve-femoral head contact), and 65% (11/17) of the stems. The internal sleeve had higher fretting corrosion scores than the external taper (Mean Score Difference [MSD] = 1.1; p = 0.001) and stem (MSD = 0.7; p = 0.016). Fretting corrosion scores were correlated with implantation time at all surfaces (Rho ≥ 0.53; p ≤ 0.015). Scores were not correlated with sleeve dimensions (p > 0.05). Fretting corrosion scores of the external sleeve correlated directly with activity level (p = 0.005) and inversely with patient age (p = 0.03). Discussion. The retrieval data shows that fretting corrosion can occur in these components, particularly on the internal surface of the sleeve. The corrosion scores were similar to levels observed in prior studies of tapers in CoCr heads [2]. Implantation time was the main predictor of increased fretting corrosion. The impact of ceramic material and sleeve design currently remain unclear as the analyses were confounded with implantation time. Thus, more detailed and quantitative analyses are required to fully determine the factors that influence fretting corrosion of sleeved ceramic heads in THA

Introduction. Mechanically assisted crevice corrosion (MACC) of head-neck modular taper junctions is prevalent in virtually all head neck tapers in use today. To date, no clear in vitro tests of design, material or surgical elements of the modular taper system have been reported that show which factors principally affect MACC in these tapers. Possible elements include seating load, head-neck offset, surface roughness, taper engagement length, material combination, angular mismatch, and taper diameter. The goals of this study were to use an incremental fretting corrosion test method. 1. to assess the above 7 elements using a design of experiments approach. The hypothesis is that only one or two principal factors affect fretting corrosion. Methods. A 2. 7-2. design of experiment test (7 factors, ¼ factorial, n=32 total runs, 16 samples per condition per factor) was conducted. Factors included: Assembly Force (100, 4000N), Head Offset (1.5, 12 mm), Taper Locking Position (Mouth, Throat), Stem Taper Length (0.44, 0.54 in), Stem Taper Roughness (Ground, Ridged), Taper Diameter (9/10, 12/14), and Stem Material (CoCrMo, Ti-6Al-4V). The heads were CoCrMo coupled with taper coupons (DePuy Synthes, Warsaw, IN). Test components were assembled wet and seated axially with 100 or 4000N assembly force. The assemblies were immersed in PBS and potentiostatically held at −50mV vs. Ag/AgCl. Incremental cyclic loads were applied vertically to the head at 3Hz until a 4000N maximum load was reached (See Fig. 1). Fretting currents at 4000 N cyclic load were used for comparisons while other parameters, including onset load, subsidence, micromotion and pull off load were also captured. Statistical analysis was performed using Pareto charts and Student's T-tests for single factor comparisons (P < 0.05 was statistically significant). Results. Average fretting corrosion currents at 4000 N cyclic load ranged from 0 to 23 µA for all test specimens. The primary factors that statistically affected fretting corrosion currents were head-neck offset (P<0.05) and assembly load (P<0.05). Test factors with the most significance are shown in the Pareto chart of effects (Fig 2). Assembly force, head offset, and the interaction between these two factors were the most significant effects (see Fig 3). All other factors had diminishing effects on fretting current. Note that there is a correlation between fretting currents and pull off load (Fig. 3c). A number of interactive effects were seen between factors on various output parameters (e.g., subsidence, pull off load, onset load) as well. Discussion. This work demonstrates that the principal factors affecting fretting corrosion are seating load and head-neck offset. Material combination, taper diameter, engagement length, roughness and angular mismatch were less significant effectors of fretting corrosion. This test assesses early fretting corrosion response but does not necessarily predict long-term performance where crevices and solution changes may be important. Significance. This work shows a relative comparison of the effects of multiple design, material and surgical elements on the early fretting corrosion behavior of modular tapers in vitro. Head offset and seating loads represent the most significant factors amongst those studied. For figures, please contact authors directly

Introduction. During revision surgery with a well-fixed stem, a titanium sleeve can be used in conjunction with a ceramic head to achieve better stress distribution across the taper surface. Previous studies have observed that the use of a ceramic head can mitigate the extent of corrosion damage at the taper. Moreover, in vitro testing suggests that corrosion is not a concern in sleeved ceramic heads [1]; however, little is known about the in vivo fretting corrosion of the sleeves. The purpose of this study was to investigate fretting corrosion in sleeved ceramic heads. Materials and Methods. Thirty sleeved ceramic heads (Biolox Option: CeramTec) were collected during revision surgery as part of a multi-center retrieval program. The sleeves were used in conjunction with a zirconia-toughened alumina femoral head. The femoral heads and sleeves were implanted between 0.0 and 3.25 years (0.8±0.9, Figure 1). The implants were revised predominantly for instability (n=14), infection (n=7), and loosening (n=5). Fifty percent of the retrievals were implanted during a primary surgery, while 50% had a history of a prior revision surgery. Fretting corrosion was scored using a previously described 4-point, semi-quantitative scoring system proposed by Higgs [2]. Results. Among the sleeved ceramic heads, mild-to-moderate fretting corrosion scores (Score = 2–3) were observed in 96% of internal tapers, 26% of external tapers, and 82% of the stems. On the internal taper surface, 5 sleeves had moderate fretting corrosion data (Score = 3, Figure 2). None of sleeves had severe (Score = 4) at any taper surface. Fretting corrosion scores were higher at the internal taper surface than the external taper. Implantation time was the main predictor of increased fretting-corrosion of the external sleeve tapers. Discussion. For the sleeved ceramic heads, we found that fretting corrosion can occur in these components, particularly on the internal surface of the sleeve. However, the fretting corrosion scores were predominantly mild, and lower than fretting scores of CoCr heads in metal on polyethylene bearings. Because the sleeves are Ti alloy, the corrosion products are considered to be less cytotoxic than Co and Cr. The primary limitation to this study is the short-term follow-up of these retrievals. As the fretting corrosion process is often associated with in vivo duration, future studies with longer-term implants are necessary to elucidate the long-term performance of these devices

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

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

Introduction. Bearing surfaces of metal-on-metal (MoM) hip resurfacing devices and total hip replacements (THRs) are a known source of metallic debris. Further, large diameter heads and the high friction of a MoM joint are thought to lead to fretting and corrosion at the taper interface between modular components. 1. The metal debris generated can cause significant problems on the joint area. 2. This paper investigated fretting and corrosion of femoral head-neck junctions. Variables of the head-neck junction which may have an effect on fretting and corrosion were identified with the aim of determining the key drivers so that their risk on fretting and corrosion could be reduced through design. Additionally, a Chromium Nitride (CrN) coating was assessed to determine the effect on fretting and corrosion of coating the stem (male), head (female) or both trunnion interfaces. As there is currently no standard specification for a head-neck trunnion interface and trunnion designs vary significantly across the market, this work may lead to a positive change in the design and materials used in head-neck taper interfaces for all THR devices. Methods. Suitable head and stem combinations were identified to enable individual variables such as; coating, medial-lateral (M-L) offset, head offset and taper angle to be isolated (Figure 1 and Figure 2). For the coated components a 3 μm CrN coating was applied to trunnion using electron beam physical vapour deposition (Tecvac, Cambridge, UK). Fretting and corrosion testing was carried out in accordance with ASTM F1875-98 (2009) method II procedure B. 3. following assembly of the components under a 2 kN load. Results. For the majority of the testing the CrN coating reduced the fretting and corrosion. Tests showed that increasing the M-L offset decreased the dynamic current but increased the static current. The results also demonstrated that increasing the head offset increases the fretting and corrosion. Taper angle did not appear to significantly alter either fretting or corrosion. Discussion. There are many peer reviewed papers regarding fretting and corrosion observed in vivo and the consequence of this on the patient. 4,5,6. To the author's knowledge this systematic identification of individual variables accountable for damaged caused to the taper junction is the first of its kind. Previous issues have been identified with CrN coatings. 7. , however the coating used here has already been shown to be very durable as a bearing surface coating under long term tests. 8. The results presented here are therefore encouraging as they also demonstrate that both fretting and corrosion can be reduced by the addition of a CrN coating to trunnion surfaces. The M-L offset results indicated that fretting may have different root causes to corrosion, as different trends were seen for dynamic and static currents. Increasing the head length increased fretting and corrosion, while altering the taper angle had no significant effect. Further work is therefore required to establish additional trends to enable design optimisation

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

Aims. The aim of this study was to evaluate fretting and corrosion in retrieved oxidized zirconium (OxZr; OXINIUM, Smith & Nephew, Memphis, Tennessee) femoral heads and compare the results with those from a matched cohort of cobalt-chromium (CoCr) femoral heads. Patients and Methods. A total of 28 OxZr femoral heads were retrieved during revision total hip arthroplasty (THA) and matched to 28 retrieved CoCr heads according to patient demographics. The mean age at index was 56 years (46 to 83) in the OxZr group and 70 years (46 to 92) in the CoCr group. Fretting and corrosion scores of the female taper of the heads were measured according to the modified Goldberg scoring method. Results. The OxZr-retrieved femoral heads showed significantly lower mean corrosion scores than the CoCr heads (1.3 (1 to 2.75) vs 2.1 (1 to 4); p < 0.01). Mean fretting scores were also significantly lower in the OxZr cohort when compared with the CoCr cohort (1.3 (1 to 2) vs 1.5 (1 to 2.25); p = 0.02). OxZr heads had more damage in the proximal region compared with the distal region of the head. Location had no impact on damage of CoCr heads. A trend towards increased corrosion in large heads was seen only in the CoCr heads, although this was not statistically significant. Conclusion. Retrieval analysis of OxZr femoral heads showed a decreased amount of fretting and corrosion compared with CoCr femoral heads. OxZr seems to be effective at reducing taper damage. Cite this article: Bone Joint J 2019;101-B:386–389

Introduction:. Modular necks allow intra-operative adjustment of neck length, offset, and version, enabling the surgeon to better match leg length and accommodate anatomical differences. However, there have been recent reports of early fatigue failures of the neck initiating from the neck/stem taper, and some retrieved components exhibit severe fretting corrosion. 1. Fatigue testing according to ISO 7206-6 (10/9 orientation) has been shown to replicate the clinical fatigue failures, but results in relatively minor fretting and corrosion. The purpose of this pilot study was to evaluate techniques for accelerating fretting corrosion with the goal of replicating the most severely corroded clinical retrieval cases. Methods:. Constructs tested in this study consisted of a single stem and neck design (PROFEMUR modular, Wright Medical Technology). The worst case long varus neck design was evaluated in two materials: Ti6Al4V and wrought CoCr. In vitro fatigue testing in the 10/9 configuration was conducted at 10 Hz in unbuffered, aerated saline. Fretting mass loss, distraction force, and assessment of taper corrosion via SEM/EDS were measured. Methods used to exacerbate fretting corrosion are shown in Figure 2. Results:. Test results & conditions are shown in Figure-2. All of the constructs impacted per surgical technique survived 5 Mc and were similar to constructs tested under standard conditions (Figure-1a). In contrast, Ti neck constructs that were hand assembled failed in fatigue after a surprisingly small number of cycles. The hand-assembled constructs that survived 5 Mc of loading exhibited lower distraction forces, higher than normal fretting mass loss, and moderate to severe corrosion of the taper. In particular, constructs that were hand-assembled and tested at elevated temperature with a rest period had much higher fretting mass loss and a level of corrosion that is qualitatively similar to corroded retrievals (Figures-1b, d). The CoCr necks that were hand assembled survived 10 Mc, but one of them fractured during distraction, and they exhibited higher fretting and corrosion at 5 Mc (Figure-1c). The effect of adding acidified saline to the stem pocket was unclear, but elevating the temperature and adding a rest period resulted in a significant increase in fretting and corrosion. Discussion:. Pallini et al. 2. recommended light tapping based on tests that showed distraction forces were equal between hammer impacted necks and hand assembly followed by simulated normal walking. The simulated gait loads in Pallini's study were applied in line with the neck taper's axis, whereas in the present study, they were applied in the 10/9 orientation, which is considerably off-axis. It is also notable that while the CoCr necks performed significantly better than Ti necks after hand-assembly, their performance was still markedly reduced compared to well-impacted constructs. Conclusion:. This study has shown conclusively that failure to impact modular neck connections can have a devastating effect on taper fretting and corrosion, leading to early fatigue failure. Applicability to other designs and to lightly impacted necks requires further study

Background:. Previous studies regarding modular head-neck taper corrosion were largely based on cobalt chrome (CoCr) alloy femoral heads. Less is known about head-neck taper corrosion with ceramic femoral heads. Questions/purposes:. We asked (1) whether ceramic heads resulted in less taper corrosion than CoCr heads; (2) what device and patient factors influence taper fretting corrosion; and (3) whether the mechanism of taper fretting corrosion in ceramic heads differs from that in CoCr heads. Methods:. One hundred femoral head-stem pairs were analyzed for evidence of fretting and corrosion using a visual scoring technique based on the severity and extent of fretting and corrosion damage observed at the taper. A matched cohort design was used in which 50 ceramic head-stem pairs were matched with 50 CoCr head-stem pairs based on implantation time, lateral offset, stem design, and flexural rigidity. Results:. Fretting and corrosion scores were lower for the stems in the ceramic head cohort (p = 0.03). Stem alloy (p = 0.004; TMZF) and lower stem flexural rigidity (Spearman's rho = −0.32, p = 0.02) predicted stem fretting and corrosion damage in the ceramic head cohort but not in the metal head cohort. The mechanism of mechanically assisted crevice corrosion was similar in both cohorts although in the case of ceramic femoral heads, only one of the two surfaces (the male metal taper) engaged in the oxide abrasion and repassivation process. Conclusions:. The results suggest that by using a ceramic femoral head, CoCr fretting and corrosion from the modular head-neck taper may be mitigated but not eliminated. Clinical Relevance:. The findings of this study support further study of the role of ceramic heads in potentially reducing femoral taper corrosion

Introduction. Recent implant design trends have renewed concerns regarding metal wear debris release from modular connections in THA. Previous studies regarding modular head-neck taper corrosion were largely based on cobalt chrome (CoCr) alloy femoral heads. Comparatively little is known about head-neck taper corrosion with ceramic femoral heads or about how taper angle clearance influences taper corrosion. This study addressed the following research questions: 1) Could ceramic heads mitigate electrochemical processes of taper corrosion compared to CoCr heads? 2) Which factors influence stem taper corrosion with ceramic heads? 3) What is the influence of taper angle clearance on taper corrosion in THA?. Methods. 100 femoral head-stem pairs were analyzed for evidence of fretting and corrosion. A matched cohort design was employed in which 50 ceramic head-stem pairs were matched with 50 CoCr head-stem pairs based on implantation time, lateral offset, stem design and flexural rigidity. Fretting corrosion was assessed using a semi-quantitative scoring scale where a score of 1 was given for little to no damage and a score of 4 was given for severe fretting corrosion. The head and trunnion taper angles were measured using a roundness machine (Talyrond 585, Taylor Hobson, UK). Taper angle clearance is defined as the difference between the head and trunnion taper angles. Results. The fretting corrosion scores were significantly lower for the stems in the ceramic head cohort when compared with the CoCr cohort. Stem alloy and stem flexural rigidity were predictors of stem fretting and corrosion damage in the ceramic head cohort, however not for the CoCr cohort. The mechanism of mechanically assisted crevice corrosion was the same in the two cohorts, with the exception being that, only one of the two surfaces (i.e., the trunnion) engaged in the oxide abrasion and repassivation process in the ceramic cohort. There was no significant correlation observed between taper angle clearance and visual fretting-corrosion scores for trunnions in the ceramic cohort (Rho=−0.17), trunnions in the CoCr cohort (Rho=0.24), or the femoral head tapers in the metal cohort (Rho=−0.05) (Figure 1). Additionally, visual fretting-corrosion scores in the metal cohort were similar between components with distal contact (negative taper angle clearance) and components with proximal contact (positive taper angle clearance) (p=0.43 and 0.56 for head and trunnion scores, respectively). Conclusions. The results suggest that by using a ceramic femoral head, CoCr fretting and corrosion from the modular head-neck taper may be mitigated, but not completely eliminated. The findings of this study support further study of the role of ceramic heads in potentially reducing femoral taper corrosion. Taper angle clearance was not correlated with the visual fretting-corrosion scores in the ceramic or CoCr cohort in the present study. The effects of taper angle clearance may not be significant compared to other factors leading to material loss or the lack of correlation may be due to the limitations in the visual scoring method. Research is underway quantify the volume of material release from explants to better understand the reasons for reduced fretting and corrosion observed in the ceramic head cohort

Trunnionosis is an important failure mechanism of total hip arthroplasties as has recently been reported by the England and Wales national joint registry. Adverse local tissue reaction has also recently been associated with total hip arthroplasty (THA) with metal on polyethylene and ceramic on polyethylene articulations. The contributing factors in the mechanism of this failure pattern have not been elucidated, however they are likely multifactorial to include corrosion, fretting, taper design, implantation time, metal particulate debris, and wear at the metal on metal interface. Furthermore, dissimilar metallic combinations have been shown to exacerbate tribocorrosion. Authors have also reported on the use of ceramic heads to reduce trunniononis, however, tribocorrosion is still present. The majority of the literature regarding modular head neck taper fretting and corrosion involves cobalt chrome (CoCr) alloy. Little is known about head neck fretting corrosion with Oxinium femoral heads. To measure fretting, corrosion, and wear on the female tapers of retrieved Oxinium femoral heads and to determine how demographic and device factors affect these measurements. Ninety-two (92) retrieved 12/14 Oxinium heads were graded using the modified Goldberg score for subjectively grading corrosion and fretting on the taper surface. A novel silicone molding technique was validated, then applied to the female tapers of the retrievals and of two pristine Oxinium femoral heads, sizes 32+0 and 32+4. The molds were scanned using a Konica Minolta 3D laser scanner for reconstruction of the topography, dimensions, and surface features of the tapers. Geomagic software was used to align the retrieved to the pristine 3D models, allowing measurement of surface deviations (from wear) that had occurred while the heads were implanted. Patient demographic and implant data were correlated with Goldberg scores and wear deviations. The mean Goldberg score was 1.6. Goldberg scores of 1 (minimal), 2 (mild), and 3 (moderate) were present in 41 of the 92 heads (45%), 43 heads (47%), and 8 heads (8%) respectively. No implants received a score of 4 (severe). A positive significant correlation was found between length of implantation and increased female taper fretting (R = 0.436, p < 0.01). Wear deviations were significantly greater with 36mm heads compared to 32mm heads (p < 0.01) and with +4 offsets compared to 0 offsets (p = 0.013). Similar to previous work analyzing ceramic heads, Oxinium heads demonstrated predominately mild tribocorrosion grades, however do not eliminate tribocorrosion. Tribocorrosion was increased with large heads and increased offsets. This finding is consistent perhaps with greater mechanical burden that larger implants with increased offsets experience. Further investigation is needed to elucidate if Oxinium femoral heads reduce fretting and corrosion when compared to CoCr femoral heads

Introduction. Previous studies of retrieved CoCr alloy femoral heads have identified imprinting of the stem taper surface features onto the interior head bore, leading researchers to hypothesize that stem taper microgrooves may influence taper corrosion. However, little is known about the role of stem taper surface morphology on the magnitude of in vivo corrosion damage. We designed a matched cohort retrieval study to examine this issue. Methods. From a multi-institutional retrieval collection of over 3,000 THAs, 120 femoral head-stem pairs were analyzed for evidence of fretting and corrosion using a visual scoring technique based on the severity and extent of fretting and corrosion damage observed at the taper. A matched cohort design was used in which 60 CoCr head-stem pairs with a smooth stem taper were matched with 60 CoCr head-stem pairs having a micro-grooved surface, based on implantation time, flexural rigidity, apparent length of taper engagement, and head size. This study was adequately powered to detect a difference of 0.5 in corrosion scores between the two cohorts, with a power of 82% and 95% confidence. Both cohorts included CoCr and Ti-6-4 alloy femoral stems. A high precision roundness machine (Talyrond 585, Taylor Hobson, UK) was used to measure surface morphology and categorize the stem tapers into smooth vs. micro-grooved categories. Fretting and corrosion damage at the head/neck junction was characterized using a modified semi-quantitative adapted from the Goldberg method by three independent observers. This method separated corrosion damage into four visually determined categories: minimal, mild, moderate and severe damage. Results. Mild to severe damage (Fretting Corrosion Score ≥ 2) was observed in 75% of the 120 CoCr femoral heads (78% of the heads mated with micro-grooved stems (47/60), Fig. 1A) and 72% of the heads mated with smooth stems (43/60, Fig 1B). Fretting and corrosion damage was not significantly different between the two cohorts when evaluated at the CoCr femoral head bore (p =0.105, Mann Whitney test, Fig. 2A) or the male stem tapers (p =0.428, Fig. 2B). No implant or patient factors were associated with fretting corrosion; corrosion scores were not significantly associated with stem alloy in the two cohorts (p=0.669, Mann-Whitney test). Discussion. The results of this matched cohort retrieval study do not support the hypothesis that taper surfaces with micro-grooved stems exhibit increased in vivo fretting corrosion. We accounted for implant, patient, and clinical factors that may influence in vivo taper corrosion with the matched cohort design and by post hoc statistical analyses. However, this study is limited by the semi-quantitative method used for evaluating damage in these components. Therefore, additional research will be necessary to quantify the volume of metal release from these two cohorts. To view tables/figures, please contact authors directly

Introduction. Modular-neck hips have twice the rate of revision compared to fixed stems. Metal related pathology is the second most common reason for revision of implants featuring titanium stems with cobalt chrome necks. We aimed to understand the in-vivo performance of current designs and explore the rationale for their continued use. Methods. This study involved the examination of 200 retrieved modular-neck hips grouped according to the material used for their neck and stem. Groups A, B and C had neck/stems featuring CoCr/beta Ti-alloy (TMZF), CoCr/Ti6Al4V-alloy, and Ti6Al4V/Ti6Al4V respectively. Reasons for revision included pain, elevated metal ion levels and fluid collection. The stem-neck interface was assessed for severity of fretting/corrosion using metrology methods to compute linear wear penetration rate. Results. All retrieved implants with a CoCr/Ti combination showed evidence of moderate-severe fretting corrosion at the neck-stem junction. Maximum penetration depth rate in group A (median of 17.9μm/year) was higher than that in group B (median=5.8μm/year); p=0.0012 and group C (median=1.55μm/year), p=0.0095. Implant failure occurred 2-fold earlier in modular-neck hips with TMZF-alloy stems than Ti6Al4V. There was a strong correlation between severity of damage and time to revision in the TMZF group A (p < 0.0001) and between taper damage and Co levels (p < 0.0001) and Cr levels (p < 0.0012). Patient and implant data did not correlate with the amount of material loss observed, (p>0.05). Discussion. The findings are in agreement with registry data as designs with CoCr/Ti at neck/stem interfaces had the highest levels of fretting and corrosion and lower threshold for revision. Conclusion. Corrosion of metal orthopaedic implants remains of clinical concern to patients, surgeons and industry. In light of the findings, the continued use of modular-neck with a metal mismatch at the neck/stem junction is unfavourable and should be avoided

Introduction. Fretting corrosion at the Head-Neck taper interface of Large Metal on Metal (MoM), Metal on Polymer (MoP) and Ceramic on Ceramic (CoC) total hip arthroplasty (THA) remains a clinical concern. Ceramic femoral heads have gained a lot of attention more recently as a possible way to mitigate/reduce the dissolution of Cobalt Chromium ions. The objective of this study is to assess the fretting corrosion currents emanating from four material combinations for which Ti6Al4V and Co28Cr6Mo are the neck components of Co28Cr6Mo and BIOLOX®delta femoral heads at three different cyclic loads. Method. 12/14 Ti6Al4V and Co28Cr6Mo spigots (designed to geometrically represent the stem) were impacted against Ø36mm Co28Cr6Mo and BIOLOX®delta femoral heads with a static force of 2kN as shown in Figure 1. The tapers were immersed in 25% v/v diluted Foetal Bovine Serum, PBS balance and 0.03% Sodium Azide at room temperature. In-situ electrochemistry was facilitated using a 3-eletrode cell arrangement whereby the neck components were the working electrode, Ag/AgCl was the reference electrode and a platinum counter electrode completed the cell. All combinations were held at a potential of 0V vs. Ag/AgCl and the cyclic load applied unto each couple were 1kN, 3kN and 5kN at 1Hz consecutively (see Figure 2). The fretting corrosion currents were converted into cumulative charge transferred (Q) by integrating the wear enhanced corrosion current. Results and Discussion. Bergmann et al.1 plotted the loading profile of a patient weighing 1000N doing various daily living activities. In their study, the range in loading cycles vary from 1kN (standing on one leg) to ∼9kN (stumbling). For this study, Figure 2 shows the sinusoidal loading profile used and the corresponding charge transferred as a result of wear enhanced corrosion. The results reveal an increase in the cumulative charge for all four combinations as cyclic load increases. While for all combinations, no negligible amount of cumulative charge was measured at 1kN, no significant difference was observed at 3kN and at 5kN, the charge transferred from both MoM and CoM fretting couples where Ti6Al4V is the neck component were significantly lower than the couples with Co28Cr6Mo neck (see figure 3). The BIOLOX®delta – Ti6Al4V couple was observed to generate the least wear enhanced corrosion current. This, we observe, is due to thick agglomerated oxides resulting from wear and corrosion products which can adhere to the anodic fretting interface (see figure 3). Conclusion. This study reveals that for both MoM and CoM combinations, the charge transferred through wear enhanced corrosion of Ti6Al4V prove to be significantly lower than the combinations with Co28Cr6Mo alloy. Furthermore, this study proposes that the agglomeration of wear and corrosion products (oxides) can lead to the reduction of fretting corrosion currents at modular fretting interfaces as seen in combinations involving Ti6Al4V alloys. This is relevant as titanium alloys are known to form thick oxides at fretting contacts. For figures/tables, please contact authors directly.

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

Introduction. There is considerable interest in the orthopaedic community in understanding the multifactorial process of taper fretting corrosion in total hip arthroplasty (THA). Previous studies have identified some patient and device factors associated with taper damage, including length of implantation, stem flexural rigidity, and head offset. Due to the complexity of this phenomenon, we approached the topic by developing a series of matched cohort studies, each attempting to isolate a single implant design variable, while controlling for confounding factors to the extent possible. We also developed a validated method for measuring material loss in retrieved orthopaedic tapers, which contributed to the creation of a new international standard (ASTM F3129-16). Methods. Based on our implant retrieval collection of over 3,000 THAs, we developed independent matched cohort studies to examine (1) the effect of femoral head material (metal vs. ceramic, n=50 per cohort) and (2) stem taper surface finish (smooth vs. microgrooved, n=60 per cohort). Within each individual study, we adjusted for confounding factors by balancing implantation time, stem taper flexural rigidity, offset, and, when possible, head size. We evaluated fretting and corrosion using a four-point semiquantitative score. We also used an out-of-roundness machine (Talyrond 585) to quantify the material loss from the tapers. This method was validated in a series of experiments of controlled material removal on never-implanted components. Results. In the first study, the ceramic cohort exhibited a 92% reduction in cumulative volumetric loss from both the head and neck taper surfaces compared to the CoCr cohort (p < 0.001). In the CoCr cohort, there was greater material loss from femoral head tapers as compared with stem tapers (p < 0.0001). There was also a correlation between visual scoring and volumetric material loss (ρ = 0.67, p < 0.01). In the second study, taper damage was not different between the smooth and microgrooved taper cohorts when evaluated at the head bore (p=0.14) or the stem tapers (p=0.35). There was also no difference in material loss between the most damaged CoCr heads in the two cohorts (p>0.05). Conclusions. Our findings suggest that fretting and corrosion damage and material loss from the stem taper are mitigated, and on the head taper, eliminated with the use of a ceramic vs. metal femoral head. We also found that fretting and corrosion damage was insensitive to differences in stem taper surface finish and the presence of microgrooves. Although visual scoring was effective for preliminary screening to separate tapers with no or mild damage from tapers with moderate to severe damage, it was not capable of discriminating within the large range of material loss observed at the taper surfaces with high fretting-corrosion scores. Thus, for moderate to severely damaged conical tapers, direct measurement is necessary. A drawback of a matched cohort approach is that a large retrieval collection is necessary to effectively match an investigational group of implants with an appropriate control cohort. Notwithstanding this limitation, the matched cohort approach has been an effective approach to study the complex multifactorial problem of taper fretting and corrosion

Background. Fretting corrosion at the junction of the modular head neck interface in total hip arthroplasty is an area of substantial clinical interest. This fretting corrosion has been associated with adverse patient outcomes, including soft tissue damage around the hip joint. A number of implant characteristics have been identified as risk factors. However, much of the literature has been based on metal on metal total hip arthroplasty or subjective scoring of retrieved implants. The purpose of this study was to isolate specific implant variables and assess for material loss in retrieved implants with a metal on polyethylene bearing surface. Methods. All 28mm and 32 mm femoral heads from a 12/14 mm taper for a single implant design implanted for greater than 2 years were obtained from our institutional implant retrieval laboratory. This included n = 56 of the 28 mm heads (−3: n = 10, +0: n = 24, +4: n = 13, and +8: n = 9), and n = 23 of the 32 mm heads (−3: n = 2, +0: n = 8, +4: n = 1, and +8: n = 6). There were no differences between groups for age, gender, BMI, or implantation time. A coordinate measuring machine was used to acquire axial scans within each head, and the resulting point clouds were analyzed with a custom Matlab program. Maximum linear wear depth (MLWD) was calculated as the maximum difference between the material loss and as-machined surface. Differences in MLWD for head length, head diameter, stem material, and stem offset were determined. Results. Within the 28 mm head diameter group, there was no difference (p = 0.65) in MLWD between head lengths (−3: 4.0 ± 1.7 µm, +0: 10.4 ± 15.2 µm, +4: 4.4 ± 1.7 µm, +8: 4.3 ± 1.8 µm). There was no difference (p = 0.12) between the 28 mm (6.7 ± 10.9 µm) and 32 mm (5.5 ± 6.2 µm) head diameters. There was also no difference (p = 0.97) between titanium (7.3 ± 11.4 µm) or cobalt-chromium (5.9 ± 5.6 µm) stems, and no difference (p = 0.20) between regular (7.0 ± 10.0 µm) or high-offset (5.7 ± 8.0 µm) stems. Discussion. The development of fretting corrosion at the head neck junction of metal on polyethylene total hip replacements is of substantial clinical importance. In a single taper design, head diameter, head length, stem material and stem offset were all not found to be contributory to magnitude of wear depth. This is in contrast to current literature, which is controversial regarding the role of head diameter, but head length is thought to be contributory. However, as this study using precise tools does not illustrate these proposed biomechanic factors of fretting corrosion, other factors influencing tribocorrosion such as trunnion surface finish, flexural rigidity, interface geometry and biochemical factors may need to be considered

Background. Hip resurfacing has advantages for the young active patient with arthritis; maintaining a large range of motion, preserving bone stock, and reduced dislocation risk. However high serum metal ion levels with metal-on-metal resurfacing, and their clinical implications, has led to a decline in the use of hip resurfacing. Ceramic bearing surfaces display the lowest frictional torque and excellent wear rates. Recent developments have enabled large, strong ceramic materials to be used as resurfacing components. Any wear debris that is generated from these articulations is inert. However an all-ceramic hip resurfacing could be at risk of fracture at the head-stem junction. A new ceramic hip resurfacing system with a titanium-ceramic modular taper junction has been developed. The introduction of a taper introduces the potential for fretting corrosion; we sought to determine the extent of this in an in-vitro model, and compared this prosthesis to the conventional 12/14 titanium-cobalt chrome (Ti6Al4V-CoCr) taper junction. Methods. To simulate the gait cycle, sinusoidal cyclical loads between 300N-2300N, at a frequency of 3Hz, were applied to different head-neck offsets generating different bending moments and torques. The effect of increasing the bending moment and frictional torque were tested separately. Furthermore, the resurfacing head was mounted in a fixture held with just the stem, thus representing complete bone resorption under the head. An electrochemical assessment using potentiostatic tests at an applied potential of 200mV, was used to measure the fretting current (μA) and current amplitude (μA). In a short-term 1000 cycle test, six neck lengths (short to xxx-long) of the Ti6Al4V-CoCr taper were compared to the standard neutral (concentric), and 3mm A/P offset stem options for the resurfacing design. To represent frictional torque, four increments of increasing torque (2-4-6-8Nm) were applied to both tapers. In a long term test with the resurfacing stem, the worst-case scenario of the eccentric offset option and 8Nm of torque were applied, and potentiostatic measurements were taken every million cycles, up to 10 million cycles. Results. For bending moment through the centre of the head, the standard neutral resurfacing taper displayed equivalent fretting current (1.35μA) compared to its conventional taper equivalent, the short 12/14 Ti6Al4V-CoCr taper (Fig. 1a). That was despite the bending moment through the resurfacing taper being higher due to the offset nature of its taper in relation to the centre of the head. For applied torque, the resurfacing taper displayed reduced average fretting current and average maximum fretting current when compared to the conventional taper (Fig. 1b), though this did not reach statistical significance (Kruskal-Wallis test). Under long term testing for worst-case bending and torque, the resurfacing taper displayed low fretting currents (<2μA and <5μA respectively) with no significant variance of the median values across 10 million cycles (Figs. 2 and 3). Conclusion. When compared to the gold-standard taper junction, the LIMA ceramic hip resurfacing displays equivalent fretting corrosion for bending moment and improved fretting corrosion for frictional torque. Across long term testing, stable and low fretting currents at this taper junction highlight its potential in clinical use