Background. Adverse local tissue reactions (ALTR) in metal-on-polyethylene (MoP) total hip arthroplasty (THA) with head-neck taper corrosion is likely to be multifactorial involving implant and patient factors. However, there is a paucity of clinical data on implant parameters as predisposing factors in MoP head-neck taper corrosion. The aim of this study was to identify any potential implant factors associated with failed MoP THA due to head-neck taper corrosion. Methods. A total of 67 MoP THA patients in two groups was investigated: 1) ALTR (n=38) on MARS MRI and 2) non-ALTR (n=29) on MARS MRI. All patients had highly cross-linked polyethylene liners with cobalt-chromium femoral heads with a single head-neck modularity. Parameters compared between groups included: acetabular component orientation, femoral neck shaft angle, radiographic measurement of medial and vertical femoral offsets, limb length discrepancy, component size, femoral head offset, implant type, femoral stem alloy and taper design. Results. The occurrence of ALTR was associated with increased femoral head offset (non-ALTR vs. ALTR, 0.5 ± 3.7 vs. 4.1 ± 3.6, p = 0.008), increased radiographic femoral stem offset (35.9 ± 7.4 mm vs 40.7 ± 7.1mm, p = 0.018), and the use of TMZF alloy stems (p = 0.051). The presence of ALTR was significantly associated with higher cobalt (9.1 µg/L vs. 0.4µg/L, p=0.001) and chromium (2.6µg/L vs. 0.4µg/L). A significant correlation was identified between the serum cobalt level and the femoral stem offset (R=0.375, p=0.009). Conclusions. Although the occurrence of head-neck taper corrosion in MoP THA is likely to be an interplay between implant and patient factors, the results of this study identified increased femoral head and stem offset and the use of TMZF alloy stems as risk factors associated with clinically relevant ALTR due to head-neck taper corrosion in MoP THA patients. The study provides evidenced-based information in risk stratification of symptomatic MoP THA patients for head-neck taper corrosion. For any tables or figures, please contact the authors directly

Summary

Corrosion and fretting damage at the head-neck interface of artificial hip joints is more severe with larger head sizes. This is a concern, as the release of metal particles and ions can cause adverse tissue reactions, similar to those observed high wear metal-on-metal articulations.

Aims. This study investigates head-neck taper corrosion with varying head size in a novel hip simulator instrumented to measure corrosion related electrical activity under torsional loads. Methods. In all, six 28 mm and six 36 mm titanium stem-cobalt chrome head pairs with polyethylene sockets were tested in a novel instrumented hip simulator. Samples were tested using simulated gait data with incremental increasing loads to determine corrosion onset load and electrochemical activity. Half of each head size group were then cycled with simulated gait and the other half with gait compression only. Damage was measured by area and maximum linear wear depth. Results. Overall, 36 mm heads had lower corrosion onset load (p = 0.009) and change in open circuit potential (OCP) during simulated gait with (p = 0.006) and without joint movement (p = 0.004). Discontinuing gait’s joint movement decreased corrosion currents (p = 0.042); however, wear testing showed no significant effect of joint movement on taper damage. In addition, 36 mm heads had greater corrosion area (p = 0.050), but no significant difference was found for maximum linear wear depth (p = 0.155). Conclusion. Larger heads are more susceptible to taper corrosion; however, not due to frictional torque as hypothesized. An alternative hypothesis of taper flexural rigidity differential is proposed. Further studies are necessary to investigate the clinical significance and underlying mechanism of this finding. Cite this article: Bone Jt Open 2021;2(11):1004–1016

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

The use of large-diameter metal-on-metal (MoM) components in total hip arthroplasty (THA) is associated with an increased risk of early failure due to adverse local tissue reaction to metal debris (ARMD) in response to the release of metal ions from the bearing couple and/or head-neck taper corrosion. The aim of this paper was to present a review of the incidence and natural history of ARMD and the forms of treatment, with a focus on the need for and extent of resection or debulking of the pseudotumour. An illustrative case report is presented of a patient with an intra-pelvic pseudotumour associated with a large diameter MoM THA, which was treated successfully with revision of the bearing surface to a dual mobility couple and retention of the well-fixed acetabular and femoral components. The pseudotumour was left in situ. Resolution of the intra-pelvic mass and normalisation of metal ion levels was observed seven months post-operatively. Cite this article: Bone Joint J 2016;98-B:736–40

Recent issues related to trunionosis have created a new paradigm in choosing femoral head material in total hip arthroplasty. While many consider highly-crosslinked polyethylene (XLPE) to be the gold standard currently in acetabular liner bearing surface, the debate remains whether metal or ceramic heads are best paired with XLPE. Wear characteristics are similar within an order of magnitude when comparing cobalt chrome femoral heads with ceramic when used in combination with XLPE. Therefore, discernable differences between the two femoral head materials with respect to outcomes would be the result of other biomechanical factors. Notably the fretting and corrosion of metal heads at the modular taper of femoral components is a serious concern and represents a significant deterrent when considering this material. The fretting corrosion that occurs with metal femoral heads has recently been well documented in multiple reports, and can be associated with adverse local tissue reactions necessitating revision hip arthroplasty. Frictional torque has recently been implicated in taper corrosion at modular junctions. In a recent simulated in vivo study, large diameter CoCr femoral heads were associated with increased frictional torque compared to smaller metal heads, supporting recent taper corrosion retrieval studies. In one recent series, a 1.1% incidence of head-neck taper corrosion with a metal head was reported and the authors recommended use of ceramic femoral heads. The notable downside of ceramic femoral heads is the implant cost and potential for fracture. However, the incidence of femoral head fracture with the newer mixed delta ceramic heads is exceptionally low and infrequent (rate 1.7 per 100,000). Furthermore, the incidence of taper corrosion is negligible with ceramic heads, making it the bearing couple of choice among many surgeons in combination with XLPE

Aims

Head-taper corrosion is a cause of failure in total hip arthroplasty (THA). Recent reports have described an increasing number of V40 taper failures with adverse local tissue reaction (ALTR). However, the real incidence of V40 taper damage and its cause remain unknown. The aim of this study was to evaluate the long-term incidence of ALTR in a consecutive series of THAs using a V40 taper and identify potentially related factors.

There is increasing global awareness of adverse reactions to metal debris and elevated serum metal ion concentrations following the use of second generation metal-on-metal total hip arthroplasties. The high incidence of these complications can be largely attributed to corrosion at the head-neck interface. Severe corrosion of the taper is identified most commonly in association with larger diameter femoral heads. However, there is emerging evidence of varying levels of corrosion observed in retrieved components with smaller diameter femoral heads. This same mechanism of galvanic and mechanically-assisted crevice corrosion has been observed in metal-on-polyethylene and ceramic components, suggesting an inherent biomechanical problem with current designs of the head-neck interface.

We provide a review of the fundamental questions and answers clinicians and researchers must understand regarding corrosion of the taper, and its relevance to current orthopaedic practice.

Cite this article: Bone Joint J 2016;98-B:579–84.