Low wear rate of UHMWPE against zirconia ceramic (Y-PSZ) in comparison to alumina ceramic and SUS 316L alloy

Partially stabilized zirconia ceramic is being recognized among ceramics for its high strength and toughness. With this ceramic, is possible to manufacture a 22-mm-size femoral head for low friction arthroplasty of the hip joint in association with an ultra-high-molecular-weight polyethylene socket. Wear-resistant properties of zirconia ceramic were screened on two principally different wear devices. Sterile calf bovine serum, physiological saline, and distilled water were chosen as the lubricant fluid media. Depending on the lubricant medium, the wear factor of polyethylene against zirconia ceramic counterfaces was 40 to 60% less than that against alumina ceramic counterfaces, and 5 to 10 times lower than with the SUS316L metal counterfaces. Polyethylene wear against metal was more susceptible in saline in which it had 2 to 3 times higher wear rate than with serum. On the other hand, different fluid media had little effect on polyethylene wear against ceramic counterfaces. In each set of tests, the wear factor obtained on an unidirectional wear device showed 10 to 15 times higher values, in comparison to the wear factor estimated on a reciprocating wear device.     

The wear behavior of ion-implanted Ti-6A1-4V against UHMW polyethylene

Nitrogen-ion-implanted Ti-6A1-4V against UHMW polyethylene was tested on a joint simulator to evaluate the wear behavior under different conditions. It was concluded that the polymer wear rate was not affected by ion implantation. The metallic wear, on the other hand, was substantially reduced by this treatment. It was also found that ion implantation resulted in good protection of the metal surface against third-body wear by PMMA, while the introduction of C.P. titanium particles in the joint initiated tremendous wear. Although ion implantation improved the wear of titanium alloy against UHMW polyethylene, the durability of the implanted layer needs further study.     

New prospects for a prolonged functional life-span of artificial hip joints by using the material combination polyethylene/aluminium oxide ceramin/metal

Investigations over the years have shown that the mirror-finished Al2O3 ceramic is a much more suitable frictional counterpart to ultrahigh molecular weight (UHMW) polyethylene than metal. Despite the extremely gread hardness difference between polyethylene and Al2O3 ceramic, a considerable lower wear rate is obtained for the polyethylene socked with this new low-friction material combination. The unexpectedly favorable tribological behavior of this ceramic material in contact with polyethylene may be attributed to the following factors: better values for corrosion resistance characteristics, wettability with liquids, surfact gloss, hardness, and scratch resistance of the ceramic material in comparison with those of the hitherto used metallic implant materials (AISI-316L steel or cast Co-Cr-Mo alloy). It appears that, by using this new combination of materials for the socket and the ball, it will be possible to prolong the service life of artificial hip joints considerably without having effecy any fundamental changes in the present design and implantation principle retaining the hitherto used anchorage shaft made of wrought Co-Ni-Cr-Mo-Ti alloy Protasul-10 of extremely high corrosion fatigue strength.     

Ceramic bearing surfaces in total artificial joints: resistance to third body wear damage from bone cement particles

Studies of explanted Charnley hip prostheses have shown damage or scratching of the polished stainless steel femoral heads. This surface damage is probably due to third body wear by bone cement particles. Damaged femoral heads will produce increased wear rates of ultra high molecular weight polyethylene (UHMWPE) acetabular cups. Sliding wear tests carried out in the laboratory have shown that alumina ceramic counterfaces are more resistant to third body damage from bone cement particles than stainless steel counterfaces. The use of the ceramic femoral heads in artificial hip joints will help to preserve the smooth surface finish on the femoral bearing surface, which is necessary to ensure low wear rates of the UHMWPE cup throughout the lifetime of the prosthesis.     

Ion implantation effects on friction and wear of joint prosthesis materials

The literature contains many results from in vitro friction and wear tests for simulating the behaviour of human joint prostheses. However, they are difficult to correlate, even when they are not contradictory. In friction tests, several friction-mechanisms occur when the Ti-6AI-4V titanium alloy rubs against the UHMWPE polyethylene. Corrosion effects which increase wear happen when the 316L stainless steel is used in Ringer's solution. Ion implantation surface treatments have been performed on these three materials. When the operating conditions were optimized, an important reduction of wear and corrosion was observed. The property improvements are due to structural modifications in a thin layer of the materials.     

Histiocyte reaction in rabbit femurs to UHMWPE, metal, and ceramic particles in different sizes.

To assess the histologic reaction caused by biomaterial particles in different sizes around the bone-implant interface, we examined ultra-high molecular weight polyethylene (UHMWPE, average diameter of 11 microm), UHMWPE (99 microm), cobalt-chromium alloy (Co-Cr, 3.9 microm), stainless steel (SUS316L, 3.9 microm), alumina ceramics (3.9 microm), titanium alloy (Ti, 3.5 microm), Co-Cr (0.03 microm), and Ti (0.03 microm). After the longitudinal groove on a polymethylmethacrylate plug was filled with one type of the particles, the plug was inserted into the medullar canal of the distal end of rabbit femurs, and tissue block was resected 4 and 12 weeks after the insertion. Histiocytes were markedly accumulated around the particles of UHMWPE (11 microm), Co-Cr (3.9 microm), SUS316L (3.9 microm), Co-Cr (0.03 microm), and titanium alloy (0.03 microm). Around the UHMWPE particles (99 microm), a slight histiocytic reaction and bone formation were observed. Particles of alumina ceramics (3.9 microm) and titanium alloy (3.5 microm) which were in phagocytosable sizes also had few histiocytic reactions. Statistically, the material difference was more strongly related to the histiocyte reaction than to the particle size and calculated total surface area of particles. Our findings demonstrate that particles of different biomaterials and in different sizes induce different foreign-body histological reactions.     

The influence of titanium surface treatments on the wear of medical grade polyethylene

Abnormally high wear rates of ultra high molecular weight polyethylene have been associated with sliding against freshly polished titanium. The wear rate can be brought to the level associated with stainless steel and cast Co-Cr-Mo alloy on polyethylene by the growth of a passive film on titanium. This can be accomplished either in air at elevated temperatures or in oxidizing aqueous solutions.     

An in vitro investigation of diamond-like carbon as a femoral head coating

Wear of polyethylene acetabular components of hip implants is a significant clinical problem. In prosthetic hip surgery, polyethylene wear is identified as a factor that limits the life of the implant; it is known that the production of debris can cause adverse tissue reactions that may lead to extensive bone loss around the implant, and consequently loosening of the fixation. A new class of so-called Diamond-Like Carbon coatings, applied to titanium femoral heads was compared to ceramic and metallic heads in terms of wear behavior against UHMWPE using a hip joint simulator with a bovine calf serum lubricant. A thin film of Diamond-Like Carbon was deposited directly onto titanium (Ti6Al4V) head using chemical vapor deposition. The wear of polyethylene coupled with Diamond-Like Carbon coated femoral heads was comparable to that obtained with the polyethylene coupled with commercial alumina femoral heads.     

Effect of counterface roughness on the wear of conventional and crosslinked ultrahigh molecular weight polyethylene studied with a multi-directional motion pin-on-disk device

The effect of counterface roughness on the wear of conventional gamma-sterilized, and electron-beam-crosslinked ultrahigh molecular weight polyethylene was studied with a circularly translating pin-on-disk device. The counterfaces, CoCr disks, were either polished, or roughened so that they represented the type of roughening and the range of surface roughness values (R(a) = 0.014-0.24 microm) observed in explanted femoral heads of total hip prostheses. The lubricant was diluted calf serum, and the test length 3 million cycles. A total of 24 tests were done. With both types of polyethylene, there was a strong correlation between R(a) and wear factor k. The power equations were k = 5.87 x 10(-5)(R(a))(0.91) for conventional polyethylene (R(2) = 0.94), and k = 7.87 x 10(-5)(R(a))(2.49) for crosslinked polyethylene (R(2) = 0.82). Crosslinking improved wear resistance significantly. The wear of crosslinked polyethylene against the roughest counterfaces was lower than the wear of conventional polyethylene against the polished counterfaces. Against rough counterfaces, the wear of crosslinked polyethylene was an order of magnitude lower than that of conventional polyethylene. On the crosslinked polyethylene pins that were tested against polished counterfaces, remains of original machining marks were still visible after the test. The average size of wear particles produced by both types of polyethylene against rough counterfaces was similar, 0.4 microm, whereas that produced by conventional and crosslinked polyethylene against polished counterfaces was significantly smaller, 0.2 and 0.1 microm, respectively.     

Some new studies of the wear behavior of ultrahigh molecular weight polyethylene.

The wear rate of ultrahigh molecular weight (UHMW) polyethylene over a long campaign of sliding distance is not constant. Both unfilled and graphite filled polyethylene show a high rate early, which reduces to a low value. The graphite-filled product shows a late stage increase in wear rate. Increased molding temperature reduces the molecular weight and increases the wear rate. Titanium articulating with UHMW polyethylene develops frequently an abnormally high wear rate with the generation of a black wear product.     

Mixed oxides prosthetic ceramic ball heads. Part 1: effect of the ZrO2 fraction on the wear of ceramic on polythylene joints.

Although mixed oxides ceramics have been indicated in the literature as a promising compromise between strength and wear, to the authors' knowledge no reports are available on the influence of the percentage of zirconia in ceramic femoral heads when sliding against polyethylene cups. Two types of mixed oxides ceramic ball heads (alumina plus, respectively, 60 and 80% of zirconia) were compared to pure zirconia and pure alumina heads in terms of wear behaviour against UHMWPE in a hip joint simulator. Polyethylene cups and ceramic femoral heads were fixed on a simulator apparatus with a sinusoidal movement and load in presence of bovine calf serum. The experimental results did not show significant difference between the two experimental ceramic materials or in comparison with pure materials. Considering that all specimens, regardless of the material, had the same level of surface roughness, this roughness factor seems to have a more relevant role than the mix of oxides used to manufacture the ceramic head. Wear tests are conducted on materials used in prosthetic hip implants in order to obtain quality control and to acquire further knowledge of the tribological processes that involve joint prostheses, therefore reducing the risk of implant failure of innovative prostheses.     

Wear resistance of experimental Ti-Cu alloys

After using cast titanium prostheses in clinical dental practice, severe wear of titanium teeth has been observed. This in vitro study evaluated the wear behavior of teeth made with several cast titanium alloys containing copper (CP Ti+3.0 wt% Cu; CP Ti+5.0 wt% Cu; Ti-6Al-4V +1.0 wt% Cu; Ti-6Al-4V+4.0 wt% Cu) and compared the results with those for commercially pure (CP) titanium, Ti-6Al-4V, and gold alloy. Wear testing was performed by repeatedly grinding upper and lower teeth under flowing water in an experimental testing apparatus. Wear resistance was assessed as volume loss (mm(3)) at 5kgf (grinding force) after 50,000 strokes. Greater wear was found for the six types of titanium than for the gold alloy. The wear resistance of the experimental CP Ti+Cu and Ti-6Al-4V+Cu alloys was better than that of CP titanium and Ti-6Al-4V, respectively. Although the gold alloy had the best wear property, the 4% Cu in Ti-6Al-4V alloy exhibited the best results among the titanium metals. Alloying with copper, which introduced the alpha Ti/Ti(2)Cu eutectoid, seemed to improve the wear resistance.     

The effect of frictional heating and forced cooling on the serum lubricant and wear of UHMW polyethylene cups against cobalt-chromium and zirconia balls

Hip simulator tests of femoral balls of cobalt-chromium alloy or zirconia against acetabular cups of UHMW polyethylene were run with and without a coolant circulated inside the femoral balls. Without cooling, the wear of polyethylene against zirconia was about 48% lower than with cobalt-chromium alloy, but the steady-state temperature of the zirconia ball was higher (55 degrees C vs. 41 degrees C), and there was more precipitation of protein from the serum, which sometimes formed an adherent layer on the surface of the zirconia. Circulating coolant at 1-20 degrees C markedly reduced the bearing temperatures and the protein precipitation. With coolant at 4 degrees C, wear of the polyethylene against cobalt-chromium alloy was about 26% lower than against zirconia, but the macroscopic and microscopic appearance of the worn polyethylene surfaces were unlike that typically generated in vivo. With or without coolant, the morphology of the polyethylene wear debris was comparable to that generated in vivo, but the ratio of fibrillar to granular debris was higher at the reduced temperature. These results suggested that circulating coolant at an appropriate temperature could avoid overheating (due to non-stop running of the simulator), preventing excessive protein precipitation while providing wear surfaces and wear debris with morphologies closely comparable to those generated in vivo.     

Adsorption of albumin on prosthetic materials: implication for tribological behavior

The orthopedic prosthesis used to substitute damaged natural joints are lubricated by a pseudosynovial fluid that contains biological macromolecules with potential boundary lubrication properties. Proteins are some of those macromolecules whose role in the lubrication process is not yet completely understood. In a previous work, we investigated the influence of the presence of albumin, the major synovial protein, upon the tribological behavior of three of the most used pairs of artificial joint materials: ultra high molecular weight polyethylene (UHMWPE) against counterfaces of alumina, CoCrMo alloy, and 316L stainless steel. Albumin was found to cause a significant decrease in the friction coefficient when the counterfaces were metallic because transfer of UHMWPE was avoided, but this effect was much weaker in the case of alumina. The objective of the present work was to look for an explanation for these differences in tribological behavior in terms of albumin adsorption. With this goal, studies on adsorption of bovine serum albumin (BSA) on the counterface materials, from a biological model fluid (Hanks' balanced salt solution), were carried out using radiolabeled albumin ((125)I-BSA), X-ray photoelectron spectroscopy, and atomic force microscopy. The conclusion from all techniques is that the driving force for albumin adsorption is higher on the metals than on alumina. These results confirm that the greater the amount of protein adsorbed on the counterface, the more efficient is the protection against the transfer of polymeric film to the counterface.     

In vitro corrosion of Ti-6Al-4V and type 316L stainless steel when galvanically coupled with carbon.

In vitro corrosion experiments were conducted employing potentiostatic polarization techniques, a saline environment and candidate biomaterial alloy/carbon combinations. Corrosion currents and potentials of carbon/metal couples were predicted by mixed-potential theory utilizing the polarization curves generated. The alloys examined were annealed ELI grade Ti-6A1-4V and cold-worked 316L stainless steel while the types of carbon examined were LTI pyrolytic carbon and vapor-deposited carbon. It was determined that galvanic couples of carbon to cold-worked 316L stainless steel with carbon/metal area ratios of 10:1 to 100:1 produced coupled corrosion potentials in the range of the observed breakdown potential of the stainless steel. It was therefore predicted that localized corrosion in the form of pitting could occur on the cold-worked stainless steel when coupled to carbon with area ratios of 10:1 or greater. The titanium alloy did not exhibit a breakdown potential up to a potential of 1.2 V. Therefore, accelerated corrosion was not predicted for the titanium alloy to carbon galvanic couples under these experimental conditions. Direct carbon/alloy coupling experiments were conducted to verify the corrosion currents and potentials predicted from mixed-potential theory and polarization curve analysis. The experimental and theoretical values showed good agreement.     

A study of the wear resistance of three types of clinically applied UHMWPE for total replacement hip prostheses.

Ultra high molecular weight polyethylene (UHMWPE) is routinely used as one half of a bearing couple in clinical orthopaedic applications. This material is generally one of two grades, compression moulded GUR 1120, with a molecular weight of 4.4x 10(6) g mol(-1), or ram extruded GUR 4150HP with a molecular weight of 7.3x10(6) g mol(-1) although other grades are used as well. This study examines the effect of molecular weight and processing method by comparing the wear resistance of these two materials together with a non-standard extruded form of GUR 1120. Wear studies have been conducted against counterface surfaces which represent new and scratch-damaged femoral heads with bovine serum lubricant in a uniaxial reciprocating test configuration. No difference in the wear resistance was found between any material when tested against smooth cobalt chrome counterfaces. On rough cobalt chrome counterfaces, although no statistically significant difference (P>0.05) was found between the extruded and compression moulded GUR 1120, the extruded GUR 4150HP had a consistently better wear resistance. These results are discussed with reference to previous wear studies as well as the physical and mechanical properties of these materials.     

Evaluation of metallic and polymeric biomaterial surface energy and surface roughness characteristics for directed cell adhesion

Directed cell adhesion remains an important goal of implant and tissue engineering technology. In this study, surface energy and surface roughness were investigated to ascertain which of these properties show more overall influence on biomaterial-cell adhesion and colonization. Jet impingement was used to quantify cellular adhesion strength. Cellular proliferation and extracellular matrix secretion were used to characterize colonization of 3T3MC fibroblasts on: HS25 (a cobalt based implant alloy, ASTM F75), 316L stainless steel, Ti-6Al4V (a titanium implant alloy), commercially pure tantalum (Ta), polytetrafluoroethylene (PTFE), silicone rubber (SR), and high-density polyethylene (HDPE). The metals exhibited a nearly five-fold greater adhesion strength than the polymeric materials tested. Generally, surface energy was proportional to cellular adhesion strength. Only polymeric materials demonstrated significant increased adhesion strength associated with increased surface roughness. Cellular adhesion on metals demonstrated a linear correlation with surface energy. Less than half as much cellular proliferation was detected on polymeric materials compared to the metals. However the polymers tested demonstrated greater than twice the amount of secreted extracellular matrix (ECM) proteins on a per cell basis than the metallic materials. Thus, surface energy may be a more important determinant of cell adhesion and proliferation, and may be more useful than surface roughness for directing cell adhesion and cell colonization onto engineered tissue scaffoldings.     

Advanced biomaterials used for a new telescopic retainer for removable dentures

Removable dentures supported by cast-metal telescopic crowns often exhibit an unpredictable increase or decrease in retentive force after being in clinical use for some time. The objective of the present in vitro study was to develop a new retainer for removable dentures and to evaluate its tribological properties. The new retainer is based on a tapered crown design and consists of a conical all-ceramic abutment crown and a coping made of electroplated gold. It was compared with conventional telescopic retainers made of cast metal. There were 30 specimens in groups of equal size by material used (abutment crown/coping): Group 1, gold/gold; Group 2, titanium/titanium; Group 3, ceramic/electroplated gold. Each specimen consisted of 2 conical-shaped abutment crowns (alpha =4 degrees; h = 6 mm; O(base) = 4,5 mm); their copings were rigidly connected at 25 mm intervals. Retentive forces were measured with a universal testing machine following axial loading to 5-400 N. Wear was simulated by 500-100, 000 joining and separating cycles in the presence of artificial saliva. Metallographic cross-sections were made to evaluate the specimens' fit and surfaces with an SEM. Retentive forces in Groups 1 and 2 increased with load, exhibiting nondirectional changes after induced wear. Sometimes the alloys' functional surfaces showed considerable tracks of wear. Neither load nor wear had any effect on Group 3 retentive forces (mean(force) = 5.03 N). The functional ceramic and gold surfaces showed no traces of wear and the best fit (median(gap) = 4.9 microm). Replacing cast metals by ceramics and electroplated gold results in retainers with clinically advantageous tribological effects, implying, in particular, high wear resistance.     

Biocompatibility of materials for total joint replacement.

The clinical use of total joint prostheses demands absolute biocompatibility of the materials employed. The purpose of this experiment was the bioassay of some materials considered as possible candidates for use in total joint prostheses as load-bearing members or as wear-resistant surfaces. Some materials already in use were also tested. 316L stainless steel was used as a control. The materials were implanted as a standardized rod and in particulate form. An average of 12 samples per material were implanted in soft tissue for six months and a total of 145 rabbits were used in this study. Twenty-five materials including metals, polymers, and ceramics were tested in solid and powdered form. A semiquantitative evaluation of local tissue reaction and a study of organs was performed. Polymers and metallic materials showed in general a mild tissue reaction. Ceramics, which some authors describe as the best tolerated materials, elicited variable tissue responses. Some of these (glass-ceramics) presented very poor tissue tolerance. The least reactive, titanium oxide, titanium aluminate, and aluminum oxide, presented a degree of tissue reaction comparable to that of corrosion resistant metals, but not superior to them. Moderate reactivity was the general rule for particulate materials except for the Pyroceram glass-ceramics, polymides, and Teflon. Ultrahigh molecular weight polyethylene in particulate form elicited a rather cellular tissue response, a fact to be considered when projecting long-term results in total joint arthroplasty. No pathological changes compatible with systemic toxicity by materials tested were observed in the study of the organs.     

Component wear of total knee prostheses using Ti-6A1-4V, titanium nitride coated Ti-6A1-4V, and cobalt-chromium-molybdenum femoral components

A knee simulator was used to study the wear of carbon fiber reinforced UHMWPE (Poly Two) (Poly Two is a registered trademark of Zimmer, USA) tibial and patellar components against Ti-6A1-4V, titanium nitride (TiN)-coated Ti-6A1-4V, and cobalt-chromium-molybdenum femoral components. The prostheses tested were regular sized Miller-Galante total knees mounted on 316L stainless steel fixtures using bone cement. An environmental chamber surrounded the knee and maintained bovine serum lubricant at 37 degrees C. The specimens were tested using consecutive blocks of 464 level walking steps, 8 ascending stairs and 8 descending stairs for a total of 100,000 steps. The wear mechanisms found on the tibial components were scratching, carbon-fiber associated damage, surface deformation, pitting, minor abrasion, and delamination. Three forms of carbon fiber associated damage were identified; fibers pulled from the surface, broken fibers, and UHMWPE removed from the surface fibers. The SEM evaluation revealed a pit forming mechanism. No correlation was found between femoral component material and tibial surface damage. Visual examination of the femoral components revealed no signs of wear or scratching on the cobalt-chromium-molybdenum or TiN-coated Ti-6A1-4V components. There were, however, many light surface scratches on the uncoated Ti-6A1-4V components, which were also observed in a supplementary test of an uncoated Ti-6A1-4V component tested with a conventional polyethylene tibial component.