Fracture of contemporary femoral stems is a rare occurrence. Earlier THR stems failed due to design issues or post manufacturing heat treatments that weakened the core metal. Our group identified and analyzed 4 contemporary fractured femoral stems after revision surgery in which electrochemical welds contributed to the failure.

All four stems were proximally porous coated titanium alloy components. All failures occurred in the neck region post revision surgery in an acetabular cup exchange. All were men and obese. The fractures occurred at an average of 3.6 years post THR redo (range, 1.0–6.5 years) and 8.3 years post index surgery (range, 5.5–12.0 years). To demonstrate the effect of electrocautery on retained femoral stems following revision surgery, we applied intermittent electrosurgical currents at three intensities (30, 60, 90 watts) to the polished neck surface of a titanium alloy stem under dry conditions.

At all power settings, visible discoloration and damage to the polished neck surface was observed. The localized patterns and altered metal surface features exhibited were like the electrosurgically-induced damage priorly reported.

The neck regions of all components studied displayed extensive mechanical and/or electrocautery damage in the area of fracture initiation. The use of mechanical instruments and electrocautery was documented to remove tissues in all 4 cases.

The combination of mechanical and electrocautery damage to the femoral neck and stem served as an initiation point and stress riser for subsequent fractures. The electrocautery and mechanical damage across the fracture site observed occurred iatrogenically during revision surgery. The notch effect, particularly in titanium alloys, due to mechanical and/or electrocautery damage, further reduced the fatigue strength at the fractured femoral necks. While electrocautery and mechanical dissection is often required during revision THA, these failures highlight the need for caution during this step of the procedure in cases where the femoral stem is retained.

Known risk factors for early periprosthetic femur fracture (PFF) following total hip arthroplasty (THA) include poor bone quality, surgical approach and cementless implants. The association between femoral component size and alignment and the risk of early PFF is not well described. We evaluated radiographic parameters of femoral component sizing and alignment as risk factors for early PFF.

From 16,065 primary cementless THA, we identified 66 cases (0.41%) of early PFF (<90 days from index THA) at a single institution between 2016–2020. The stem was unstable and revised in all cases. We matched 60 cases of early PFFs (2:1) to 120 controls based on femoral component model, offset, surgical approach, age, BMI, and sex. Mean age was 67 years; 60% were female. Radiographic assessment of preoperative bone morphology and postoperative femoral component parameters including stem alignment, metaphyseal fill, and medial congruence with the calcar. A multivariable logistic regression was built to identify radiographic risk factors associated with early PPF.

Markers of poor preoperative bone quality including canal calcar ratio (p=0.003), canal flare index (p<0.001), anteroposterior canal bone ratio (CBR) (p<0.001) and lateral CBR (p<0.001) were statistically associated with PFF. Valgus alignment (23% versus 12%) (p<0.001) was more prevalent in the PFF group compared to controls, as well as varus alignment of the implant (57% versus 43%). Distance between the medial aspect of the implant and the calcar was greater in cases of PFF (2.5 mm versus 1.4 mm) (p<0.001). Multivariate analysis demonstrated that valgus implant alignment (Odds Ratio (OR) 5) and medial implant-calcar incongruity (OR 2) increased the risk of early PFF.

Medial implant-calcar incongruity and valgus alignment of the femoral component were risk factors for early PFF following cementless THA after controlling for age, sex, BMI, approach, proximal femoral morphology, and implant design.