Millions of people suffer from bone and joint inflammatory problems and usually result in extreme cases with total joint replacement. Most commonly affected joints are the hip and the knee. Over the past 20 years there has been a revival in interest of metal-on-metal hip replacements. Various alloys have been used in joint replacement, the most successful in the Cobalt-based alloys. As compared to others the cobalt based alloys have higher wear resistance and therefore less risk of failure. The most common Co-based alloy used in clinical application is the ASTM F75 alloy, which is extensively used in femoral and acetabular components. Conventional methods to fabricate the alloy are via cast or wrought techniques. Wrought alloys are better than their cast materials due to their superior mechanical properties as the forging process promotes plastic deformation. An alternative method of fabrication is via powder processing and has shown significant improvements to produce finer grained materials, which relate to enhancement in properties, such as strength, toughness, ductility.

One of the key stages of powder processing is sintering of the powder to fuse the particles together. A superior but simple sintering processing is spark plasma sintering (SPS), which produces highly dense materials with minimum grain growth. This is achieved by a pulsed electrical current heating the material while applying a pressure to compact the powdered material. This process has the ability to densify nanopowders, in order to produce microstructures with finer grains and superior mechanical properties.

Using SPS and nanopowders for the first time, we have been able to prepare the ASTM F75 cobalt–chromium–molybdenum (Co–Cr–Mo) orthopaedic alloy composition. In this work we have investigated, the effect of processing variables on the structural features of the alloy (phases present, grain size and microstructure). We have been able to produce specimens of >99% of the theoretical density. The structures were free of carbides, which a vital breakthrough. Detrimental carbide phases in the microstructure as found in the more conventional methods of fabrication have shown to cause problems in wear. The compacts are of higher hardness than cast or wrought products despite the absence of carbides in the microstructure. The gain in hardness is because of the presence of oxides in the microstructure and we hope to quantify the oxide content in the future. The mechanisms of oxide formation are explained by considering chemical thermodynamics and kinetics. The next step is to evaluate the tribological performance (wear, friction, lubrication regimes) of this SPS-processed material and compare its performance with conventional MoM products (cast and wrought). The SPS route offers significant advantages over the conventional cast and wrought routes used to prepare this alloy for orthopaedic applications.

Introduction; In contrast to hydroxyapatite (HA), carbonate substituted hydroxyapatite (CHA) is resorbed by osteoclasts, and is more osteoconductive in vivo. On bone, osteoclastic resorption results not only in topographical changes, but also changes in the proteinaceous matrix within the resorption pit to which osteoblasts respond [1]. This study sought to investigate a possible link between the different bioresorptive properties of these biomaterials and subsequent bone formation on their surfaces, analogous to the coupling seen in normal bone remodelling.

Methods; Phase-pure HA and 2.7wt% CHA were prepared by aqueous precipitation methods [2] and processed into dense sintered discs for cell culture. Human osteoclasts derived from CD14+ precursors were cultured for 21 days on discs of HA and CHA; subsequently, cells and the proteinaceous layer were removed from some discs leaving a topographically altered surface (assessed by SEM and profilometry), whilst in others the proteinaceous layer was left intact. Control (unresorbed) discs were also prepared. The discs were then seeded with human osteoblasts (HOBs) which were cultured for up to 28 days, in some cases in the presence of hydrocortisone and â-glycerophosphate. Proliferation (MTS assay), collagen synthesis (3-H Proline incorporation), and the formation of mineralised nodules (tetra-cycline labelling [3] and SEM) were assessed.

Results; Osteoclasts altered the ceramic surfaces. Large pits were seen on CHA in contrast to limited erosion of the HA surface, accompanied by a greater increase surface roughness (Ra) (p< 0.05). After 6 days of culture, proliferation of HOBs was increased on resorbed discs provided the proteinaceous layer resulting from osteoclastic activity was left intact. At 28 days, cells had formed confluent sheets and there were no significant differences in their number. At 6 days, collagen synthesis by HOBs on CHA was increased on resorbed surfaces, and further increased if the proteinaceous layer was left intact. A similar response was seen on HA, but not until 28 days. Mineralised nodules formed after 28 days of culture in the presence of hydrocortisone and â-glycerophosphate on tissue culture plastic, but not in their absence. By contrast on the ceramics there was no evidence of mineralised nodule formation on any of the discs, although globular accretions were present in small amounts throughout the collagenous matrix regardless of the presence or absence of supplements.

Conclusion; Prior osteoclastic activity on HA and CHA affects subsequent proliferation and collagen production by HOBs. The effects of topographical alteration and matrix conditioning appear synergistic, and are apparent at an earlier time-point on a more resorbable ceramic. Osteoclastic activity may be important in the osteoconductive properties of biomaterials.

Our aim was to analyse the influence of the size, shape and number of particles on the pathogenesis of osteolysis. We obtained peri-implant tissues from 18 patients having revision surgery for aseptically loosened Freeman total knee replacements (10), Charnley total hip replacements (3) and Imperial College/London Hospital double-cup surface hip replacements (5). The size and shape of the polyethylene particles were characterised using SEM and their concentration was calculated. The results were analysed with reference to the presence of radiological osteolysis.

The concentration of polyethylene particles in 6 areas with osteolysis was significantly higher than that in 12 areas without osteolysis. There were no significant differences between the size and shape of the particles in these two groups.

We conclude that the most critical factor in the pathogenesis of osteolysis is the concentration of polyethylene particles accumulated in the tissue.

Torsional instability of femoral components has not received much attention, and is difficult to detect in conventional radiographs. To test this we designed a system to apply a load in an anteroposterior direction to the head of a femoral component, implanted into a cadaveric femur. Rotation within the bone was measured, using a purpose built transducer, with and without preservation of the neck, with and without cement, and with longitudinal ridges but no cement. The results show that torsional instability may be a problem in uncemented replacement. Preservation of the femoral neck and the use of a ridged prosthesis increases resistance to rotation. Rotational movements occurring in vivo during such activities as climbing stairs and rising from the seated position may contribute to mechanical loosening.