Background

Complications of metal-on-metal hip resurfacing, leading to implant failure, include femoral notching, neck fracture, and avascular necrosis. Revision arthroplasty options include femoral-only revision with a head, however mis-matching radial clearance could accelerate metal ion release. Alternatively, revision of a well-fixed acetabular component could lead to further bone loss, complicating revision surgery. We have developed a ceramic hip resurfacing system with a titanium-ceramic taper junction; taking advantage of the low frictional torque and wear rates that ceramic affords. Taking a revision scenario into account, the ceramic head has a deep female taper for the resurfacing stem, but also a superficial tapered rim. Should revision to this resurfacing be required, any femoral stem with a 12/14 taper can be implanted, onto which a dual taper adaptor is attached. The outer diameter of the taper adaptor then becomes the male taper for the superficial taper of the ceramic head; ultimately allowing retention of the acetabular component. In an in-vitro model, we have compared the fretting corrosion of this taper adaptor to existing revision taper options: a titanium-cobalt chrome (Ti-CoCr) taper junction, and a titanium-titanium sleeve-ceramic (Ti-Ti-Cer) taper junction.

Background

Hip resurfacing has advantages for the young active patient with arthritis; maintaining a large range of motion, preserving bone stock, and reduced dislocation risk. However high serum metal ion levels with metal-on-metal resurfacing, and their clinical implications, has led to a decline in the use of hip resurfacing. Ceramic bearing surfaces display the lowest frictional torque and excellent wear rates. Recent developments have enabled large, strong ceramic materials to be used as resurfacing components. Any wear debris that is generated from these articulations is inert. However an all-ceramic hip resurfacing could be at risk of fracture at the head-stem junction. A new ceramic hip resurfacing system with a titanium-ceramic modular taper junction has been developed. The introduction of a taper introduces the potential for fretting corrosion; we sought to determine the extent of this in an in-vitro model, and compared this prosthesis to the conventional 12/14 titanium-cobalt chrome (Ti6Al4V-CoCr) taper junction.

Introduction

Recent studies on large diameter femoral head hip replacements have implicated the modular taper junction as one of the significant sources of wear and corrosion products and this has been attributed to increased torque and bending on the taper interface. The aim of this study was to assess the effect of frictional torque and bending moment on fretting corrosion at the taper junction and to investigate whether different material combinations also had an effect.

The aim of this study was to assess the effect of frictional torque and bending moment on fretting corrosion at the taper interface of a modular femoral component and to investigate whether different combinations of material also had an effect. The combinations we examined were 1) cobalt–chromium (CoCr) heads on CoCr stems 2) CoCr heads on titanium alloy (Ti) stems and 3) ceramic heads on CoCr stems.

In test 1 increasing torque was imposed by offsetting the stem in the anteroposterior plane in increments of 0 mm, 4 mm, 6 mm and 8 mm when the torque generated was equivalent to 0 Nm, 9 Nm, 14 Nm and 18 Nm.

In test 2 we investigated the effect of increasing the bending moment by offsetting the application of axial load from the midline in the mediolateral plane. Increments of offset equivalent to head + 0 mm, head + 7 mm and head + 14 mm were used.

Significantly higher currents and amplitudes were seen with increasing torque for all combinations of material. However, Ti stems showed the highest corrosion currents. Increased bending moments associated with using larger offset heads produced more corrosion: Ti stems generally performed worse than CoCr stems. Using ceramic heads did not prevent corrosion, but reduced it significantly in all loading configurations.

Cite this article: Bone Joint J 2015;97-B:463–72.

Aim:

The aim of this study was test the amount of corrosion occurring at the (Ti) /cobalt chrome (CoCr) interface comparing this with Ti and Ti interfaces. This was compared with retrieved metal work visualised under a scanning electron microscope (SEM).

Introduction:

There has been widespread concern regarding the adverse tissue reactions after metal-on-metal (MoM) total hip replacements (THR). Concerns have also been expressed with mechanical wear from micromotion and fretting corrosion at the head/stem taper junction in total hip replacements. In order to understand the interface mechanism a study was undertaken in order to investigate the effect of surface finish and contact area associated with modular tapers in total hip replacements with a single combination of materials of modular tapers.

Introduction:

High failure rates with large diameter, metal on metal hip replacements have highlighted a potential issue with the head/stem taper junction as one of the significant sources of metal ion release. Postulated reasons as to why this may be such a problem with large head metal on metal hip replacements is due to the increased torque achieved by the larger head size. This may be responsible for applying greater micromotion between the head and stem taper and consequently greater amounts of fretting corrosion. The aim of this study was to perform short term in vitro electrochemical tests to assess the effect of increasing head diameter and torque on the fretting corrosion susceptibility of the head/stem taper interface and to investigate its effect on different material combinations.

Material loss at the head-stem taper junction may contribute to the high early failure rates of stemmed large head metal-on-metal (LH-MOM) hip replacements. We sought to quantify both wear and corrosion and by doing so determine the main mechanism of material loss at the taper. This was a retrospective study of 78 patients having undergone revision of a LH-MOM hip replacement. All relevant clinical data was recorded. Corrosion was assessed using light microscopy and scanning electron microscopy, and graded according to a well-published classification system. We then measured the volumetric wear of the bearing and taper surfaces. Evidence of at least mild taper corrosion was seen in 90% cases, with 46% severely corroded. SEM confirmed the presence of corrosion debris, pits and fretting damage. However, volumetric wear of the taper surfaces was significantly lower than that of the bearing surfaces (p = 0.015). Our study supports corrosion as the predominant mechanism of material loss at the taper junction of LH-MOM hip replacements. Although the volume of material loss is low, the ionic products may be more biologically active compared to the particulate debris arising from the bearing surfaces.

It has been speculated that high wear at the head-stem taper may contribute to the high failure rates reported for stemmed large head metal-on-metal (LH-MOM) hips. In this study of 53 retrieved LH-MOM hip replacements, we sought to determine the relative contributions of the bearing and taper surfaces to the total wear volume. Prior to revision, we recorded the relevant clinical variables, including whole blood cobalt and chromium levels. Volumetric wear of the bearing surfaces was measured using a coordinate measuring machine and of the taper surfaces using a roundness measuring machine. The mean taper wear volume was lower than the combined bearing surface wear volume (p = 0.015). On average the taper contributed 32.9% of the total wear volume, and in only 28% cases was the taper wear volume greater than the bearing surface wear volume. Despite contributing less to the total material loss than the bearing surfaces, the head-stem taper junction remains an important source of implant-derived wear debris. Furthermore, material loss at the taper is likely to involve corrosion and it is possible that the material released may be more biologically active than that from the bearing surface.

The articulating surface replacement (ASR) XL stemmed total hip replacement and ASR resurfacing hip systems were recalled by DePuy due to a high prevalence of early failure. The ASR XL has a greater failure rate than the ASR resurfacing, which has been increasingly attributed to wear and corrosion at the taper interface between the female taper surface of the femoral head and the male taper (trunnion) of the femoral stem. The aim of this study was to quantify the prevalence and severity of taper corrosion in retrieved ASR XL hip components.

A peer-reviewed subjective corrosion scoring system was used to quantify corrosion in a consecutive series of the 50 ASR XL hip components (head components – n=44; femoral stems – n=6) at our retrieval centre. Bearing surface wear (femoral head and acetabular cup combined) was quantified and a value of <5 microns was defined as low-wearing. Subsequent profilometry analysis was undertaken in the low-wearing hips to quantify material loss from the taper interface.

90% of components showed evidence of corrosion, with at least moderate corrosion observed in 58%. There were 17 low-wearing hips which had a median material loss from the taper interface of 3.51mm³ (range: 0.612–9.443). The median linear depth of material loss was 33μm (range: 8.5–78.0). No relationship was observed between taper corrosion and serum cobalt (r=0.204, p=0.2712) or chromium (r=0.146, p=0.432) metal ions.

Wear and material loss from metal-on-metal (MoM) hips is associated with pseudotumour formation and adverse soft-tissue reactions. We have shown that taper corrosion is extremely common in failed ASR XL hips and that wear occurs in the same degree of magnitude as at the bearing surface also occurs at the taper interface. Therefore our findings support the emerging concept of ‘taper failure’, whereby the taper is the predominate reason for failure of MoM hips. Future work must determine the relative contributions of the bearing surface and the taper interface to serum cobalt and chromium metal ion levels.

Corrosion at the taper interface between the femoral head and the femoral stem is well described in metal-on-polyethylene (MoP) hips but previously was undetermined in large diameter head metal-on-metal (LHMoM) hips. The high failure rate of the articulating surface replacement (ASR) XL hip system has been partly attributed to susceptibility to corrosive damage at the taper interface. It was not known if other hip manufacturers are liable to taper corrosion. Therefore the aim of this study was to quantify the prevalence and severity of taper corrosion in LHMoM hips and compare corrosion across five different current generation manufacturers.

Taper corrosion was analysed in a consecutive series of the five most common hip types at our retrieval centre: ASR XL, DePuy (n=49); Birmingham hip resurfacing, Smith & Nephew (n=33), Durom, Zimmer (n=31), M2a Magnum, Biomet (n=14) and Cormet, Stryker (n=10). A four-scale peer-reviewed qualitative corrosion scoring system was used to quantify corrosion (none, mild, moderate and severe).

Evidence of corrosion was observed in 86% of components, with at least moderate corrosion observed in 61%. No difference in corrosion was observed between the ASR XL and the other manufacturers (p=0.202). There was still no difference seen when all manufacturers were compared individually (p=0.363). A positive correlation was observed between corrosion and femoral head diameter (r=0.224, p=0.021). However no relationship was observed with implantation time (r=0.163, p=0.118).

Our study indicates that taper corrosion is common in LHMoM hips and affects all hip types equally. The clinical significance of this finding is that all hip types will be susceptible to the complications of corrosion, such as third body wear and osteolysis. Furthermore recent reports indicate that corrosive debris released from the taper interface may play a role in the formation of pseudotumours and adverse soft-tissue reactions. We found that larger femoral head sizes showed greater corrosion, which suggests that high torque increases fretting corrosion of the taper interface. Future work must determine the optimum femoral head size and investigate the chemical composition of the corrosive debris.

In metal-on-metal (MoM) total hip arthroplasty, the taper interface is where the femoral head (female taper surface) attaches to the trunnion (male taper) of the femoral stem. Corrosion is well reported in metal-on-polyethylene hips but little is known about taper corrosion in MoM devices. The aim of this study was to quantify corrosion in modern-generation stemmed MoM hip systems and gain insight into the nature of the underlying corrosive attack.

Taper corrosion was quantified in 161 failed MoM components (head components n=128; femoral stem n=33) from nine hip types with the use of a qualitative subjective scoring system. An unanticipated finding on preliminary inspection of the hips was a region on the female taper surface that contained ridges that directly corresponded with the ridged microthread on the trunnion. The ridges were not present on unimplanted (control) female taper surfaces and therefore a novel four-scale subjective scoring system was devised to quantify the prevalence and severity of this ‘imprinting’ phenomenon.

Evidence of corrosion was observed in 81% (131/161) of components, with at least moderate corrosion observed in 58% (94/161). Corrosion was greater on the female taper surface than on the male taper (p=0.034) and the two scores were associated (r=0.784, p=0.001). Imprinting affected all manufacturers and was observed in 64% (82/128) of head components. The corrosion and imprinting scores were strongly correlated (r=0.694, p=0.001). Corrosion was largely confined to the area of the female taper interface where imprinting had occurred i.e. the region that had been in contact with the trunnion microthread. Scanning electron microscopy showed evidence of fretting corrosion and substantial mechanical wear within the ridged region on the female taper surface.

Our study indicates that MoM hips are susceptible to taper corrosion. We believe it occurs by a process of “mechanically-assisted crevice corrosion,” involving the following sequence of events: joint fluid enters the taper junction as a result of pumping of fluid along the machined microthread of the trunnion. This results in galvanic corrosion of the anodic surface (the cobalt-chromium femoral head or taper sleeve). The pattern of corrosion of the head taper is determined by the surface profile of the screw thread of the trunnion, thus leaving an imprinted appearance. Historically the ridged microthread was introduced to trunnions to minimise the risk of burst fracture of ceramic heads. However this study indicates that the ridges are detrimental in MoM hips by causing extensive mechanical wear. Thus the possibility that cobalt-chrome and ceramic femoral head components require different trunnion designs needs urgent investigation.

Purpose

To investigate the incidence of deep vein thrombosis (DVT) and pulmonary embolism (PE) with external fixator use and to help establish whether current guidelines are appropriate.

Introduction

No published work exists regarding deep vein thrombosis (DVT) and pulmonary embolism (PE) incidence with the elective use of external fixators. The aim of this work was to establish the rate of DVT and PE in such cases to help inform whether thromboprophylaxis guided by risk factors is adequate or if a more aggressive approach is required.