Modern hip implants feature a modular design, whereby the individual components of the implant are assembled during the surgery. Increased reported failure rates associated with the utilization of modular junctions have raised many clinical concerns about the increased release of metal ions/debris leading to adverse local tissue reactions. Implant materials are subject to a myriad of mechanical motion and forces, and varying electrochemical conditions and pH changes from the surrounding environment. To date, no studies have attempted to model the collected data in order to predict the performance of the materials so that precautions can be taken before the problem reaches the critical stage. This study reports the effects of pH variation, displacement variation, and load variation on the mechanical and corrosion behavior of the hip implant modular junction system, tested with a custom-built fretting-corrosion apparatus. The main objective of this study is to combine the complete data set of the in-vitro experiments to create fretting-corrosion wear maps that can predict the dangerous domains of the hip implant modular system.

For each test, the flat portions of two CoCrMo pins were loaded perpendicularly against a Ti6Al4V Rod (Ti alloy) in a Flat-on-flat configuration in a simulated synovial fluid in order to simulate the modular hip implant system. A schematic diagram of contact conditions is presented in Figure 1. A sinusoidal displacement was applied onto the rod, which articulated against the CoCrMo alloy pins, at a frequency of 1Hz. The experiential data from the fretting-corrosion tests has been used to create fretting-corrosion maps. The variables incorporated into the maps include: total mass loss, electrochemical destabilization, pH variation, load variation, displacement variation, and visual examination of the wear features of the contact zone. Total mass loss has been estimated via measurement of the simulator fluid by ICP-MS technique. Electrochemical destabilization was evaluated by a single parameter (V_Drop). The electrochemical destabilization of the tribosystem was evaluated by measuring the drop in potential, V_Drop (V vs. SCE), resultant from the initiation of the fretting phase. The V_Drop refers to the initial cathodic drop in potential in response to the initial onset of fretting motion.

The data from the in vitro fretting-corrosion experiments has been combined to create four fretting-corrosion maps (Figures 2A–3D). Partial slip wear features and mechanical behavior was observed at 25µm displacement. 25–150µm displacement amplitudes showed gross slip behavior. Anything larger than 150µm displayed wear features that were indistinguishable from sliding wear. In general, total mass loss and V_Drop increased with increasing displacement. Samples that were tested at pH 6.0 or higher showed signs of material transfer and higher V_Drop. Finally, there was a general decrease in V_Dropwith increased applied load and pH.

In general, the wears maps were able to offer some predictive validity, however, there were some discrepancies between visual observations and the observed damage parameters. It is possible that other parameters could offer better correlation. Future studies will be conducted to measure other parameters.

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