Due to their superior wear characteristics, oxidized Zr-2.5Nb heads are used with hip stems made of conventional orthopaedic alloys. Galvanic interactions between Zr-2.5Nb (Zr) and Ti-6Al-4V (Ti), cobalt-chromium (CoCr), and 316L stainless steel (SS) alloys were evaluated.

Galvanic current density was measured for Zr/Ti,Zr/CoCr, Zr/SS, CoCr/Ti, and CoCr/SS couples under static conditions in aneutral Ringer’s solution and in an acidic (1.7 pH) solution. To simulate fretting, one or both coupled alloys in the neutral solution subsequently were abraded by a bone cement pin (82 MPa Hertzian stress). An extended(7-day) static test in the acidic solution was performed for Zr/SS and CoCr/Ti to simulate crevice conditions. The dissolved metal ion concentration was determined using direct coupled plasma emission spectrometry.

Mean initial current densities of the Zr/SS, SS/CoCr,Zr/CoCr, CoCr/Ti, and Zr/Ti couples were 3.0, 0.36, 0.16, 0.05, and 0.04μA/cm2, respectively, in the neutral solution, and 0.57, −0.29, 0.04, 0.02, and 0.03 μA/cm2, respectively, in the acidic solution (positive when first alloy was anode). Within 30 minutes, all values decreased below 0.02μA/cm2. The current densities increased by orders of magnitude under fretting conditions. When both alloys were abraded, the highest values were minus;677 and 464 μA/cm2 for CoCr/Ti and Zr/SS, respectively. In the extended static test of Zr/SS, the mean total metal ion concentration decreased from 8.15 mg/L when the alloys were uncoupled to 4.50 mg/L(p=0.007) when they were coupled. For CoCr/Ti, the change from 1.28 to 1.72mg/L when the alloys were coupled was not statistically significant(p=0.22).

With its strong tendency to passivate, the Zr alloy produced galvanic interactions within the range observed with conventional alloy couples. Its anodic characteristic helped protect SS in a galvanic couple.