With the boom in metal-on-metal hip resurfacing and hard-on-hard total hip replacements (THRs) with extremely low wear, accurate tribological measurements become difficult. Characterizing THR friction can help in this, especially if the progress of such friction can be tracked during wear tests. Friction measurement can also be used as a tool to study the effects of acetabular-liner deformation during insertion, and possible femoral head “clamping”. This study presents estimates of friction during extended wear testing on THRs of the same size but with different material combinations, using a technique (previously introduced) based on equilibrium of forces and moments measured in the simulator.

All tests were based on five million cycles (Mc) and samples of size-44mm (head diameter). Samples included 6 metal-on-UHMWPE (MOP) (3 with conventional UHMWPE and 3 with highly-cross-linked (HXL) UHWMPE liners), 6 metal-on-metal (MOM) (3 TiN-coated and 3 uncoated), 6 MOM resurfacing (3 standard and 3 with small pockets for lubrication transport), and 3 ceramic-on-UHMWPE (COP) THRs (MOM resurfacing and COPs for 2Mc only). All were lubricated with diluted bovine serum with 20g/l protein concentration at 37°C, and subjected to the loading and rotations of the walking cycle in ISO-14242-1 on a twelve-station hip simulator (AMTI, Boston).

The conventional and HXL MOPs had steady friction factors of 0.045±0.009 and 0.046±0.003 over 5Mc, explained by the stability of wear rates of both these MOP types (72.0±2.81mg/Mc and 14.2±3.57mg/Mc, respectively). However, during the “bedding-in” period (first 0.5Mc), the conventional MOP friction factor rose from 0.047±0.004 to 0.057±0.004 while high wear was occurring (147.1±10.08mg/Mc). The TiN-coated and uncoated MOMs displayed initial friction factors of 0.124±0.117 and 0.039±0.003 respectively. The high standard deviation for the coated THRs was due to coating removal on one specimen which caused scratches and scuffs on its articulating surfaces. This specimen had a friction factor of 0.260 at 0.028Mc. By 1Mc, the TiN coating wore away on the other two coated specimens (friction factors at 1Mc: coated 0.081±0.036, uncoated 0.050±0.014). Over the 5Mc test, average friction factors for the coated and uncoated THRs were 0.097±0.020 and 0.049±0.014 respectively. The 44mm standard and “pocketed” MOM resurfacing THRs displayed initial friction factors of 0.038±0.009 and 0.059±0.026 respectively that increased to the same level at 2Mc (0.094±0.020 and 0.094±0.029, respectively). No difference in wear was detected between the two resurfacing head types (wear rates over 2Mc: standard 3.32±0.25mg/ Mc, pocketed 2.22±1.76mg/Mc), but curiously, both types exhibited an equal level of scratching and scuffing on their articular surface. Finally, the three COP THRs exhibited high liner wear over 2Mc (97.44±3.08mg/Mc), which slowed after the “bedding-in” period. The friction factor also decreased from 0.091±0.005 to 0.070±0.008 over the same period as the UHMWPE liner conformed to the ceramic head.

The method utilized here facilitates on-line sampling throughout the progress of a prolonged wear test, and therefore allows predictions on THR performance/wear to be made. When high friction factors were observed, a high wear rate was occurring and measured on the THR specimens, or damage to articulating surfaces was seen.

Statement of Purpose: Hard-on-hard bearing surfaces are finding increasing application in total hip replacements for wear reduction. Polycrystalline Diamond Compacts (PDCs) offer several potential advantages, including ultimate hardness, reduced metal ion release compared to metal-on-metal (MoM) articulations and increased strength/ toughness compared to ceramic-on-ceramic (CoC). This study investigates in-vitro wear and friction for a 28mm diamond-on-diamond (DoD) system under normal walking gait and also with distraction.

Methods: Six sets of 28mm PDC femoral heads and 28/41mm PDC acetabular liners (Dimicron, Utah) were tested on a hip simulator (AMTI, Boston). Radial clearances were 18–42 microns. Specimens were mounted anatomically with the cups superior and mounted at 45 degrees. All stations were lubricated with 37oC bovine serum diluted to 17g/l protein concentration. Components were subjected to a 3kN walking cycle (ISO14242-1) for 5 million cycles (MC). This was followed by 2MC of distraction testing with a reduced swing-phase load of 120N, an applied side force of 129N and with the abduction motion disabled. This produced approximately 0.5–0.7mm of horizontal displacement of the center of the head. The lubricant was changed and the components cleaned, dried and weighed at 0.5MC intervals.

Results: All heads and liners gained weight during each portion of the test. Potential mechanisms (still under investigation) include protein adsorption and hydration of metallic phases within the diamond compact. The weight gains were found to be somewhat reversible after drying in vacuum for extended periods (60–90 hours). However, the standard 1 hour drying cycle used for weight measurements during the test was found to be inadequate. Therefore, only the “dry weights” measured after 64–92 hours of vacuum drying at the beginning and end of each test portion were used to compute wear rates.

Overall wear rates for heads and liners for the 5MC of normal gait and the 2MC of distraction testing and for the whole 7MC. 95% confidence intervals are plotted for each set of six heads and liners. Weight changes were converted to volumetric wear using a density of 3,800kgm-3. Even after extended drying, the liners all showed small weight gains. The heads apparently wore slightly during the normal walking cycle but gained weight during the distraction cycle. Overall, the heads showed a small wear rate of 0.17±0.09mm3/MC and the liners showed a small ‘negative’ wear rate of −0.11±0.07mm3/MC. Due to the uncertainties involved in the drying procedure, it is concluded that DoD wear rates were unmeasurably low for this test. Distraction is known to increase wear rates for CoC systems [1] and might reasonably be expected to have a similar effect for DoD, due to the high elastic modulus of diamond.

However, the 2MC of distraction testing produced only small weight gains. The heads showed no evidence of ‘stripe wear’ as reported for CoC systems.

Conclusions: DoD wear rates were found to be unmeasurably low for an anatomical hip simulator test with and without distraction. Friction factors for DoD were slightly lower than for metal-on-UHMWPE.