Fracture of a ceramic liner in a total hip arthroplasty with a sandwich cup

Alumina ceramic-on-ceramic total hip arthroplasty (THA) has been widely used due to its advantages such as low wear, scratch resistance, wettable surface and relatively low biological reactivity of the wear particles. Nevertheless, this material in THA still persists to be one of the major concerns about the risk of fracture, due to its brittleness. Many authors have reported a fracture of the ceramic head but few reported a fracture of the ceramic acetabular insert. In order to reduce the rigidity of the ceramic-on-ceramic coupling and prevent an impingement between the rim of the ceramic liner and the metal neck of the femoral stem, a modular acetabular component with a sandwich insertion (alumina/polyethylene/titanium) was proposed. We report the fracture of the ceramic acetabular liner of such a ceramic sandwich cup due to a slightly retroverted position of the cup that causes an impingement between the femoral stem and the rim of the insert. The fracture occurred 3 years after the operation without trauma. At revision the entire cup was replaced using a polyethylene liner without inner ceramic liner.     

Ceramic acetabular liner fracture in total hip arthroplasty with a ceramic sandwich cup

In total hip arthroplasty, a modular acetabular component with a sandwich insertion (alumina ceramics/polyethylene/titanium) was proposed. The polyethylene layer might reduce the rigidity of the ceramics and prevent an impingement between the ceramic liner rim and the femoral neck. A case of an acetabular liner fracture of the ceramic sandwich cup was presented. The fracture occurred 1.4 years after the operation without trauma. Because the ceramic liner rim was hit by the head following the impingement between the neck and the polyethylene, the cause of the fracture might be the stress concentration at the rim of the ceramic liner, of which the thickness was only 4 mm. At revision surgery, the fractured ceramic liner was replaced with a polyethylene liner without inner ceramic liner.     

Squeaking in a Delta ceramic-on-ceramic uncemented total hip arthroplasty

Squeaking is one of the main concerns related to the use of ceramic-on-ceramic total hip arthroplasty. Although it has received much recent publicity, most of the previous reports on this complication have been related to the use of the second generation of alumina ceramics combined with a cup having an elevated metal rim to protect the ceramic liner from neck impingement. We report a patient with a third-generation Biolox Delta (CeramTec AG, Plochingen, Germany) ceramic-on-ceramic uncemented total hip arthroplasty without an elevated metal rim in the cup who presented with a squeaking hip at 23 months postoperative. Although this complication was mainly related to a specific design in the literature, this case demonstrates that newer generation of ceramics can also present squeaking.     

Early Dislocation Rate in Ceramic-on-Ceramic Total Hip Arthroplasty

Wear debris from metal-on-polyethylene articulation in conventional total hip arthroplasty (THA) may limit THA longevity. Bearing surfaces made of modern ceramic material, with high wear resistance and low fracture risk, have the potential to extend the longevity of THA and make the procedure more suitable for young, active patients. Concerns regarding a ceramic-on-ceramic bearing surface have included potential for a higher incidence of dislocation caused by limited modular neck length and liner options. This prospective study assessed the early dislocation incidence for a ceramic-on-ceramic THA system. Out of the 336 consecutive ceramic-on-ceramic THA performed at our institution over an 8-year (1997–2005) period, 2 (0.6%) sustained dislocation during, and none after, the first postoperative year. Both dislocations were treated with closed reduction. No component fracture or revision for any reason has occurred in this series. Level of Evidence: Level II Prospective cohort study     

A polyethylene liner scratch after revision hip arthroplasty performed to repair ceramic fracture

A 61-year-old man who had undergone revision total hip arthroplasty in 2000 was evaluated at our clinic in 2008, 1 day after feeling an abnormal clicking sensation in his left hip. Radiographs showed a fracture of the alumina ceramic liner of his acetabular component. A second revision total hip arthroplasty was performed with a 28-mm highly crosslinked polyethylene acetabular liner and an alumina femoral head. Sixteen months after the second revision, the patient experience sudden-onset hip pain. Radiographs revealed a fatigue fracture of the neck of a displaced stem. Analysis by scanning electron microscopy of the surface of the retrieved alumina ceramic femoral head revealed no scratches or wear, but analysis of the highly crosslinked polyethylene socket revealed third-body wear, scratches, irregularly shaped dips, and white ceramic particles. Elemental analysis of the white particles by an x-ray microanalyzer revealed the presence of aluminum and oxygen.     

Primary Ceramic-on-ceramic Total Hip Arthroplasty Using a 32-mm Ceramic Head With a Titanium-alloy Sleeve

Background

Modern ceramic-on-ceramic bearings have become attractive alternatives to conventional polyethylene in total hip arthroplasty (THA) as a result of their low wear and minimal particle production. However, 28-mm heads in ceramic-on-ceramic bearing couples have been associated with ceramic fracture. To address these issues, 32-mm and larger ceramic heads with a titanium-alloy sleeve have been introduced, although limited data are available on their durability and clinical outcomes.

Questions/purposes

We determined (1) the survivorship of the primary ceramic-on-ceramic THA using a 32-mm ceramic head with a titanium-alloy sleeve at a minimum followup of 5 years; (2) Harris hip scores; (3) the incidence of ceramic fracture and noisy hip; and (4) the proportion of hips showing radiographic evidence of osteolysis.

Methods

From November 2005 to August 2009, we performed 301 ceramic-on-ceramic THAs using a 32-mm ceramic head with a titanium-alloy sleeve in 270 patients. Of these, 12 patients (12 hips [4%]) died from problems unrelated to surgery and 13 patients (15 hips [5%]) were lost during followup before a minimum of 5 years had been reached, leaving 245 patients who had 274 THAs with a minimum followup of 5 years (mean, 6.5 years; range, 5–9 years) in this retrospective analysis. During the study period, 30% (301 of 997 hips) were performed with this articulation based on the operating surgeon’s discretion. The mean patient age at the time of surgery was 55 years (range, 16–82 years). All operations were performed at a single center. All of the ceramic implants were hot isostatic-pressed, laser-marked, proof-tested third-generation alumina. We determined the implant survival, Harris hip scores, incidence of ceramic fracture or noisy hips (based on a questionnaire), and presence of osteolysis.

Results

The survival rate of ceramic-on-ceramic bearings in primary THA using a 32-mm ceramic head with a titanium-alloy sleeve was 98% (95% confidence interval, 96%–100%) at 9 years. The Harris hip score improved from a mean of 47 points preoperatively to 93 points at last followup. One ceramic head fractured at 6 years postoperatively. No ceramic liners fractured. Audible hip clicking and squeaking were identified in four hips and one hip, respectively. Osteolysis was detected in three hips, but none had symptoms.

Conclusions

Primary ceramic-on-ceramic THA using a 32-mm ceramic head with a titanium-alloy sleeve has a survivorship of 98% at 9-year followup. Nevertheless, surgeons should be aware of the potential risks of ceramic fracture, noise, and osteolysis associated with the use of a ceramic head with a titanium-alloy sleeve.

Level of Evidence

Level IV, therapeutic study.     

Surgeons’ Awareness and Impaction Technique of a Ceramic Liner into a Metal Shell

BackgroundIn ceramic-on-ceramic total hip arthroplasty, firm locking is necessary between a ceramic liner and an acetabular metal shell to prevent dissociation of the liner from the metal shell. We evaluated surgeons’ awareness of the technique for inserting the ceramic liner and measured the impaction force applied by surgeons during the insertion of the ceramic liner.MethodsTo evaluate the awareness, we conducted a survey using a questionnaire including techniques for ceramic liner insertion. The impaction force was measured using an impaction simulator in 224 surgeons.ResultsMost surgeons answered that they cleaned and dried up the inner surface of the metal shell before inserting a ceramic liner (96.4% and 86.2%, respectively), and 74.6% checked the correct seating of the ceramic liner. However, only 23.2% correctly answered that a minimum of 2kN (a light strike) was necessary to obtain a sufficient fit between the metal shell and the ceramic liner. The impaction force was weaker than 2 kN in 9.4% of the surgeons.ConclusionsEducation about the adequate impaction force to obtain a firm fit of the ceramic liner is necessary for surgeons who perform total hip arthroplasty using ceramic-on-ceramic bearings.     

Ceramic-on-ceramic total hip arthroplasty: A new standard

Total hip arthroplasty (THA) is durable and reliable at relieving pain and improving function in patients with end stage arthritis of the hip joint. Changing patient demographics, risk for aseptic loosening, and instability remain major barriers for long-term implant survivorship. Modern ceramic bearings used in THA have enjoyed good long-term clinical track record and the reliability of these components continues to improve with better materials, surgical technique, and implant design. Coupled with excellent wear characteristics and optimum bearing lubrication with larger head sizes, modern ceramic-on-ceramic THAs can address all of these concerns without the complications of volumetric polyethylene wear associated with the use of large metal ball heads with polyethylene. Consequently, modern ceramics represent the new standard in bearing surfaces for patients undergoing hip replacement surgery.     

Uncemented third-generation ceramic-on-ceramic total hip arthroplasty using metal acetabular shell with direct taper locking liner

Background

The ceramic-on-ceramic (CoC)-bearing couple in total hip arthroplasty (THA) was developed to reduce the wear debris and osteolysis. Although the mechanical strength of third-generation ceramic has improved over previous generations, the risk of osteolysis and ceramic fracture is still an important concern.

Methods

We studied 124 uncemented THAs with third-generation CoC-bearing couple implanted between 2000 and 2004. The ceramic liner and head were secured with the direct taper locking mechanism. One hundred and eleven hips were followed-up for minimum of 8 years, with an average follow-up period of 10.1 years (range 8.0–12.8 years). Patients were evaluated with a particular emphasis on the prevalence of the osteolysis and the ceramic fracture.

Results

The survivorship with the end point as implant revision for any reason was 94.9 % (95 % confidence intervals 90.0–99.3 %) at 12.8 years. Revisions were performed because of one ceramic liner fracture, three dislocations, and two deep infections. No radiographic evidence of wear or osteolysis was observed. The preoperative Merle d’Aubigne and Postel hip score increased from 11.6 to 17.1.

Conclusions

Patients, who received third-generation CoC THA had no detectable wear and osteolysis. One ceramic fracture occurred, and the main reason for revision was dislocation.     

Serious metallosis of a metal head due to fragmented ceramic screws in a cemented THA

We reported a rare revision case necessitated by massive metallosis of a metal head due to a fragmented ceramic screw which had been extraarticularily used in the primary THA here and reviewed previous literature about metallosis of metal heads associated with ceramic materials. The ceramic screw had been used for the fixation of a bone graft and reattachment of the greater trochanter in the primary THA. Scanning electron microscope analysis revealed large alumina ceramic particles embedded on the bearing surface of the polyethylene. It has previously been pointed out that metallosis of an inner head occurred in bipolar case due to a fracture of the ceramic screws in contact with a proximally migrated outer head. However, this case showed that if a ceramic screw fragmented even though it was used outside of the hip joint, the fragments could migrate into bearing surface and cause serious metallosis of the metal head. Thus, we recommend that surgeons should pay special attention to the radiographic signs of ceramic failure or metallosis such as a change of the metal head contour, if an aseptic loosening or severe osteolysis is observed in a THA in which ceramic materials were used near the hip joint. And, when a surgical revision is planned, the surgeon should be prepared to exchange with a new ceramic head.     

Delayed fracture of a ceramic insert with modern ceramic total hip replacement

We report a case of ceramic liner fracture in a 34-year-old man that occurred 1 year 9 months after total hip arthroplasty with a BiCONTACT (Aesculap, Tuttlingen, Germany) ceramic-on-ceramic prosthesis. The ceramic liner was found within the metal shell in 4 large pieces and multiple small fragments in the peripheral portions. Its condition indicated that the possible mechanism of late ceramic liner chip fracture was repeated episodes of impingement between the prosthetic neck and the edge of the ceramic liner. Squatting, kneeling, and sitting cross-legged caused impingement. These positions are more common in Asian populations than in Western populations. After the joint was thoroughly irrigated, a new modular ceramic liner and a 28-mm ceramic head were implanted.     

Complete polyethylene wear-through and secondary breakage of the expansion cup in a ceramic-polyethylene total hip arthroplasty

Introduction

Catastrophic polyethylene failure is an uncommon complication of ceramic-on-polyethylene total hip arthroplasty (THA) because of the favourable tribological characteristics of these implants. We present a case of a 50-year-old woman who formerly underwent bilateral ceramic-on-polyethylene THA with expansion acetabular cups and eleven years later presented with unilateral THA dislocation, secondary to catastrophic polyethylene failure and metal shell fracture.

Case presentation

The patient came to our hospital for worsening pain in her left hip and an acute incapacity to bear weight on her left lower limb. Twelve and eleven years earlier she had undergone bilateral ceramic-on-polyethylene THA with acetabular expansion components of identical size on both sides. Radiographically, the left femoral head appeared superiorly dislocated and severe polyethylene wear was detected. The inclination angles of the left and right cups were 60° and 44°, respectively. The patient underwent left acetabular revision, and complete polyethylene wear-through with fracture of a cranial lobe of the expansion metal shell was noted at surgery. One large osteolytic lesion in the roof of the acetabulum and diffuse periarticular metallosis were also present. These findings required the use of a Burch–Schneider reinforcement cage. Two years later the patient is functioning well and has full autonomy in her activities of daily living.

Conclusion

The correct inclination of the acetabular component is necessary to prevent accelerated polyethylene wear in THA, even though favourable articular bearing surfaces have been used (e.g., ceramic-on-polyethylene coupling). Should the cup appear well fixed and fairly oriented on follow-up radiographies, the early detection of severe polyethylene wear may permit a revision of only the femoral head and acetabular liner.     

Use of ceramics in total hip replacement

Ceramics have been used as a bearing surface in total hip arthroplasty (THA) for more than 30 years. Properties of this material which make it particularly attractive for this application include its hardness, high compression strength, and excellent wettability. The low incidence of biologically significant particle generation and clinically significant osteolysis with the use of ceramics in THA reflects these properties. However, low fracture toughness and linear elastic behavior demonstrated by ceramic make it prone to breakage under stress. Improvements in the processing of ceramic as well as advances in engineering of head-neck articulations and liner design have led to an overall decrease in the incidence of ceramic fracture and dislocation. This article reviews the science behind the use of ceramics in THA, the clinical results of ceramics in THA, including complications unique to this bearing surface, and future directions for the application of ceramics in THA.     

Mid-term result of ceramic bearings in total hip arthroplasty

Purpose

The purpose of this study was to evaluate our clinical experience with ceramic-on-ceramic cementless total hip arthroplasty (THA) and complications after an average follow-up of more than eight years.

Methods

From January 2001 to December 2008, 540 THA with ceramic-on-ceramic bearings were performed in 448 patients (92 bilateral, 54 of which were operated simultaneously) with a mean age 49.9 years (range 18–84) by a senior surgeon. Pre-operative aetiological reasons were developmental dysplasia of the hip (DDH) in 205 hips, degenerative arthritis in 157 hips, avascular necrosis in 51 hips, rheumatoid diseases in 40 hips, posttraumatic arthritis in 40 hips, other reasons in 25 hips and revision surgery in 22 hips. Patients were evaluated with Harris hip score (HSS), and radiological findings of acetabular and femoral component loosening or osteolysis with ceramic bearing related complications like squeaking, liner and head fractures were recorded.

Result

The average duration of follow-up time was 8.2 years (range, five to 13.2). The main Harris hip score increased from 42.4 points preoperatively to 94.9 points at the time of last follow-up. We had one fracture of the ceramic head, 11 clicking and four squeaking; one of them was revised because of terrible squeaking due to acetabular liner fracture, the other three were seldom audible from the outside and followed conservatively. We did not observed loosening or osteolysis due to ceramic bearings at the time of the final follow-up.

Conclusion

Our study has demonstrated that ceramic-on-ceramic bearings can be used safely in different etiological problems. Incidences of noisy hips are becoming less frequent.     

Computer-based motion simulation of total hip prostheses with ceramic-on-ceramic wear couple. Analysis of implant design andorientation as influence parameters

OBJECTIVE: In THA, ceramic-on-ceramic wear couples are increasingly used. A restricted range of motion (ROM) due to unfavourable implant design or positioning may cause impingement or dislocation, which can result in failure of ceramic inserts. METHODS: By means of a 3-D CAD program different hip joint movements were simulated and the effects of ceramic hip implant design and position on the range of motion were analysed. RESULTS: To offer sufficient ROM and to minimise risk of impingement and dislocation, inclination angle of the acetabular cup should be 45 degrees, cup anteversion 15 degrees and stem antetorsion 0 degrees to 10 degrees. In regard to implant design, acetabular cups with slightly- recessed ceramic inserts should be used. Prosthetic systems with an elevated liner or with a mushroom-shaped femoral head are associated with limited ROM and increased risk of mechanical failure. The ratio of head to neck diameter should never be less than 2 : 1. Larger heads not only increase ROM, but also the stability of the prosthesis against dislocation. Thereby, the wear rate of ceramic-on-ceramic couples is not increased, in contrast to polyethylene. CONCLUSION: Considering certain criteria for ceramic hip implants regarding implant positioning, design and handling, ceramic-on-ceramic couples can be used with low risk of revision surgery and they can also reduce the prosthesis loosening associated with wear in young and active patients.     

Failure analysis of a ceramic bearing acetabular component

BACKGROUND: Alternative bearings have been explored in an attempt to improve the longevity of total hip prostheses. A Food and Drug Administration (FDA)-approved clinical study of a nonmodular acetabular component consisting of a porous metal shell, compression-molded polyethylene, and a ceramic liner inlay was discontinued following reports of early failures. METHODS: Between October 1999 and January 2003, 429 patients were enrolled in a prospective study to evaluate a cementless ceramic-on-ceramic total hip arthroplasty design (Hedrocel ceramic bearing cup; Implex, Allendale, New Jersey). Two hundred and eighty-two patients (315 hips) were treated with the experimental acetabular implant and 147 patients (157 hips) were treated with an acetabular implant that consisted of the same porous shell but an allpolyethylene liner. Clinical data including a Harris hip score and responses to the Short Form-12 (SF-12) health survey were collected preoperatively and at twelve and twenty-four months postoperatively. Serial radiographs were made preoperatively; at six weeks, three months, six months, and twelve months postoperatively; and annually thereafter. Retrieval analysis was performed on all failed explanted components. Failure was defined as fracture or displacement of the ceramic liner out of the acetabular component. In addition, biomechanical testing was performed on unimplanted acetabular components and mechanically altered cups in an effort to recreate the mechanisms of failure. Finite element analysis was used to estimate stress and strain within the ceramic liner under extreme physiologic loading conditions. RESULTS: The ceramic liner failed in fourteen of the 315 experimental acetabular components; all of the failures were at the ceramic-polyethylene interface. Patients with a body weight of >91 kg had a 4.76 times greater odds of the ceramic liner failing than those who weighed < or =91 kg. Retrieval analysis demonstrated stripe and rim wear with evidence of adhesive wear, indicating a potentially high-friction interaction at the articulation. Finite element analysis demonstrated that the forces on the ceramic liner in cups subjected to extreme loading conditions were insufficient to cause fracture. Biomechanical testing was unable to reproduce an initial ceramic liner displacement in vitro; however, when the ceramic liner was forcibly displaced prior to biomechanical testing, complete displacement and eventual fracture of the ceramic liner resulted. CONCLUSIONS: We hypothesized that the combination of a high patient body weight, an extensive range of motion, and subluxation of the femoral head led to high friction at the articulation between the femoral head and the rim of the liner, which initiated displacement of the ceramic liner. Subsequent normal gait led to further displacement of the liner in all of the fourteen failed components and eventually to ceramic fracture in twelve of the fourteen components.     

Total hip arthroplasty with ceramic-on-ceramic bearing failure from third-body wear

This article describes a new mechanism of failure of a ceramic-on-ceramic total hip arthroplasty (THA) due to fretting corrosion and failure of the Morse taper. A 46-year-old man with hip osteonecrosis underwent THA in 2006. A ceramic-on-ceramic, un-cemented THA with a titanium femoral component and metal-on-ceramic Morse taper was implanted. Two years postoperatively, he presented with swelling in his groin and a painless medial thigh mass. The thigh mass was diagnosed as an abscess. Incision and drainage was performed and resulted in a sinus tract that continuously drained copious amounts of seropurulent fluid. Two months later, the patient underwent irrigation, debridement, and explantation of his hip. Frozen sections showed no signs of infection. There was dramatic visible wear of the Morse taper and pieces of metal embedded in the ceramic. Permanent sections showed chronic inflammation and foreign body reaction. He subsequently underwent an uneventful re-implantation with a metal-on-highly-cross-linked-polyethylene THA. In this case, failure of the morse taper led to metal debris, which reacted with the ceramic and caused dramatic third-body wear. The thigh mass, which appeared to be an infection, proved to be a massive foreign body granuloma. Malfunction of the morse taper as reported in this case represents a possible failure mechanism of a ceramic-on-ceramic THA.     

Modern total hip arthroplasty in patients younger than 21 years

Total hip arthroplasty (THA) is not commonly performed in adolescents. However, it may be the only option for pain control with continued mobility for advanced disease. We report our experience with modern alternative-bearing THA in patients younger than 21 years. Twenty-one THAs (18 patients) were followed. Preoperative and postoperative Harris hip scores were recorded, and radiographs were reviewed. Average follow-up was 49 months (range, 25-89). Underlying etiology was chemotherapy-induced osteonecrosis (33%), steroid-induced osteonecrosis (29%), sickle cell disease (24%), and chronic dislocation (14%). Articulation bearings were ceramic/ceramic (67%), metal/highly cross-linked polyethylene (29%), and metal resurfacing (5%). Mean age was 18 years (range, 13-20). Harris hip scores improved from 43.6 to 83.6 (P < .001). At final follow-up, there was no radiographic loosening; 1 THA was revised for a cracked ceramic liner. At intermediate-term follow-up, clinical and radiographic results are favorable after alternative-bearing THA in patients younger than 21 years.     

Patterns of failure of ceramic liner in total hip replacement: report of two cases

We report two cases of ceramic liner fracture that occurred 8 months and 12 years after uncemented total hip arthroplasty (one JRI and the other one was Mittelmaier ceramic-on-ceramic prostheses). There was history of fall in one case. The ceramic liner was found within the metal shell in many large pieces and small fragments in one case and with a missing superior sector and titanium shell wear and fracture in the other. Both prostheses were revised with satisfactory outcome. The patterns of the failure of the ceramic liner seem to be acute and multifragmented following a fall and a missing sector of the line following repeated episodes of impingement between the prosthetic neck and the edge of the ceramic liner. This report highlights the fact that there are limitations of ceramic articulation in hip arthroplasty, which both the surgeon and the patient have to be aware of.     

The squeaking hip: a cause for concern-disagrees

Total hip arthroplasty with ceramic-on-ceramic bearing surfaces has demonstrated low wear with excellent clinical outcomes. More recently, concerns have surfaced because of the presence of audible squeaking in some ceramic-on-ceramic THA patients. The incidence of this phenomenon has been low and has infrequently required reoperation. The exact etiology of squeaking remains unclear but is likely related to variations in surgical technique, patient selection, and implant design, particularly those designs that result in premature femoral neck-acetabular component rim impingement such as the presence of modular ceramic liner designs that are placed within a titanium encasement which has an extended rim. Hopefully, with continued improvements in design, materials, and component positioning, squeaking following ceramic-on-ceramic THA can be minimized.