Metal Liner Research Articles

Clinical, Functional and Radiographic Outcomes of Inverted-Bearing Reverse Shoulder Arthroplasty at Minimum Two Year Follow-up

BackgroundInverted-Bearing Reverse Shoulder Arthroplasty (IB-RSA) is an alternative reverse bearing construct characterized by an ultra-high molecular weight polyethylene glenosphere combined with a CoCr metallic humeral liner. This concept was designed both to minimize bearing wear as well as reduce the potential for scapular notching seen with more traditional-bearing RSA systems. This study reports on clinical outcomes, functional scores, pain scores, and radiographic incidence of scapular notching in a series of IB-RSA at a minimum of two-year follow-up. MethodsA retrospective study was conducted on patients who underwent an IB-RSA between 2016 and 2019, with a minimum follow-up period of two years. Patients were evaluated clinically for DASH score (DS), American Shoulder and Elbow Surgeons score (ASES), EQ-5D Health Questionnaire (EQ-5D), Global Rating of Change score (GRC), Single Assessment Numeric Evaluation score (SANE) and range of motion (ROM). Presence and grade of radiographic scapular notching was assessed using the classification of Sirveaux at 6,12, 24 months and at the last x-ray available. Results61 consecutive patients were assessed at a mean postoperative follow-up of 37 months (range, 24-72 months). IB-RSA exhibited high overall outcome scores including DASH (38.3 +/-5), ASES (83 +/- 6), GRC (4 +/-0.6), and SANE (83 +/-11). ROM was assessed in 41 patients with 135 +- 21 of elevation, 23 +- 12 of external rotation and 5 +- 2 for internal rotation. Scapular notching was radiographically present in 23 (38%) patients (twenty grade 1, three grade 2) in the final follow-up, with all cases showing evidence of mechanical notching while no grade 3 or 4 cases were observed. The scapular notching didn’t progress in most of the patients after the first year (P>0.05). The presence of scapular notching did not influence on clinical outcome scores as DASH, ASES, EQ-5D, GRC, SANE (P>0.05) or active range of motion (P>0.05). ConclusionIB-RSA demonstrates high patient-reported and functional outcome scores at a minimum of two years follow-up. We report only low-grade scapular notching with little progression after the first year. There was no correlation between scapular notching and clinical outcomes.

Understanding the impact of an applied axial magnetic field on efficient current coupling on the Z machine

Magnetized liner inertial fusion (MagLIF) is an attractive concept for producing thermonuclear fusion reactions. The MagLIF platform involves the operation of Helmholtz coils to apply a 15 Tesla axial magnetic field to the load region, where a cylindrical, fuel-filled metal liner is imploded by a ∼20 MA current pulse. The fringe field from these coils extends into the transmission line that delivers the current to the target. We investigated the extent to which this applied field disturbs the nominal power flow within that transmission line. A simplified model of the geometry shows that adding the applied magnetic field results in magnetic field lines that connect the cathode to the anode, suggesting electrons may not be magnetically insulated in this region. Particle-in-cell simulations indicated the addition of the applied magnetic field would not significantly impact the current delivery to the load. Velocimetry was used to experimentally assess the current delivery with and without the applied magnetic field. We find no measurable effects of the applied field on current delivery in the configuration investigated in this study. Published by the American Physical Society 2024

Investigation of steady-state gas diffusion through angled metallised polymer films for applications in fibre reinforced pressure vessels as barrier membranes

Pressure vessels used for the storage of hydrogen gas, particularly carbon-fibre reinforced pressure vessels (CPVs), must demonstrate sufficient leak tightness. Currently, this is achieved by costly metallic liners which come at a weight disadvantage compared to CPVs. Therefore, novel concepts for designing CPVs with low permeation characteristics are of high interest for various industrial applications. In this paper, a new concept is proposed based on overlapping intersections of metallised polymer films. Manufacturing trials are carried out on a laboratory scale to demonstrate the feasibility of a new barrier membrane design that can also be integrated into the winding process of CPVs. An efficient analytical model, as well as finite element simulations, are compared against experimental findings for the permeation of Helium. The findings indicate significant promise for implementing the barrier concept in CPVs, with tests and models demonstrating an over 1000 - fold decrease in the permeability of the barrier membrane compared to pure polymer, even when utilizing unoptimized tape materials. Reductions by a factor of over 10 000 are possible with material optimisation.

Theoretical and experimental research on the critical buckling pressure of the thin-walled metal liner installed in the composite overwrapped pressure vessel

Composite overwrapped pressure vessels (COPVs) are widely used in the field of high-pressure gas storage and transportation because of their light weight and high strength. In engineering, autofrettage is usually used to improve the fatigue life of composite pressure overwrapped vessels with metal liners. However, excessive pressure of autofrettage could cause buckling damage to the metal liner. In order to determine the upper limit of autofrettage (critical buckling pressure) and analyze its influence on the safety factor of COPVs, a theoretical calculation model of the critical buckling pressure about the metal liner was established based on classical laminated plate theory and the confined buckling theory. Then, a COPV with thin-walled welded metal liner was prepared by fiber winding process. In order to monitor and judge the buckling damage mode of the liner, the circumferential strain of the COPV's cylinder was measured by loading and unloading step-by-step. Finally, the influence of materials and dimensions of the metal liner on the pressure ratio (the ratio of the first layer failure pressure to the critical buckling pressure of the COPV's metal liner) was discussed. When the diameter to thickness ratio (R/t) of the metal liner was greater than 35, the pressure ratios of the 6063-T5 aluminum alloy liner and the S30408 stainless steel liner both exceeded 2.25. However, the pressure ratio of 6061-T6 aluminum alloy liner with R/t ≤ 60 was lower than 1.85, which shows that the metal liner with higher yield strength and lower elastic modulus has higher utilization rate of fiber winding layers. Due to the fact that the current design standards only ensure the reliability of COPVs through safety factors and various type testing with their evaluation methods, the proposed theoretical calculation method can reduce the uncertainty of COPVs during the design and testing rounds.

Implosion of heavy metal liners driven by megaampere current pulses

Implosion of heavy metal liners driven by megaampere current pulses

Evaluation of Cu surface diffusion on different metal liner materials for Cu reflow applications

Evaluation of Cu surface diffusion on different metal liner materials for Cu reflow applications

Study of Design and Analysis of S-glass Fiber Reinforced Epoxy Polymer Metal Laminate Composites in the Application of Propeller Shafts

The propeller shafts are utilized to transmit power from gear box to rear wheels in automobiles. It is found that the weight, cost, critical speed and buckling of shafts are the serious issues in conventional metallic propeller shafts. The propeller shafts made up of composite material are best suited for LMV due to single piece manufacturing. The fiber metal laminate propeller shafts are getting popular as the metal liner adds extra strength, rigidity and acts as a substrate and avoids leaking during manufacturing. The propeller shaft of light motor vehicle was selected for study. S-glass fibers, epoxy and a thin mild steel liner are the materials chosen. The design of the shaft was carried out according to ASME Standard code of design. The ply orientation and stacking sequence are selected as [±45°, 0°, 90°], to increase the torsional strength, enhance natural frequency and buckling strength respectively. The finite element analysis of the propeller shaft is carried out in Ansys APDL. It is found from the analysis that the weight, torsional strength, torsional stiffness and natural frequency of the S-glass fiber reinforced Epoxy Metal Laminate (FML) composites are superior than the conventional C-35 alloy steel material, and hence can be an alternative to the conventional alloy steel shaft.

Cover Image

The cover image is based on the article Design, optimization, manufacture, and tests of CFRP hydraulic cylinder tube without metal liner: A bionic thorn‐tooth connection by Yao Li et al., https://doi.org/10.1002/pc.28504. image

Automated manufacture and experimentation of composite overwrapped pressure vessel with embedded optical sensor

In recent years, the mobility (air/land) industry has been developing fuel-cell vehicles for mass adoption as hydrogen technology matures. Compared to conventional metallic design, the composite overwrapped pressure vessel without a metal or polymer liner results in a lightweight solution for gaseous hydrogen storage which further improves fuel efficiencies. Since the capabilities of automated fiber placement for making multi-stiffened structures are distinct from other automated manufacturing techniques, this study aimed to evaluate the feasibility of implementing AFP into the manufacture of a small scale COPV with a partially composite liner. The manufacturing related challenges are identified and discussed. During the manufacturing process, Distributed fiber optic sensor was embedded between the plies, as a structural health monitoring solution, to monitor the mechanical performance of the pressurized tank. In addition, finite element study was done to predict the internal strains for different pressure levels and the measured experimental strains at the sensor's location are found to be in close agreement with the finite element results. It is shown that such sensors can be integrated into automated fiber placement manufactured tanks for internal strain monitoring.

Theoretical study on 3D elastic response and first layer failure strength of composite cylinders subjected to axisymmetric loadings

The traditional Lekhnitskii 3D elastic theory can obtain the exact stress and strain response of the composite cylinder under the axially symmetric loadings. However, when the cylinder contains 0° winding layers or isotropic layers, some calculation parameters corresponding to the two kinds of special layers will become singular. By analyzing the continuity of singular parameters and calculating their limits, the problem of singular parameters can be effectively solved and the Lekhnitskii theory can be extended to composite thick-walled cylinders with arbitrary winding angles. Furthermore, based on the Chang-Chang strength criterion of composite layers and the ideal elastic-plastic assumption of isotropic metal layers, the theoretical calculation method of first layer failure strength and the corresponding failure modes of the composite cylinders subjected to axisymmetric loadings was proposed. Then, the composite cylinder with metal liner was fabricated by fiber winding process. The experimental blasting pressure of the cylinder was 52.8 MPa with a major failure mode of fiber tensile fracture. Based on the proposed theoretical method, the cylinder's first layer failure strength of internal pressure was 44.1 MPa, and the initial failure mode was also fiber tensile fracture. The predicted result of the first layer failure strength was lower than the experimental results. The result proved the safety and economy of the proposed theoretical method for the initial design of the composite cylinder.

Numerical simulation of mechanical properties of composite high-pressure vessel for space application

Abstract A composite high-pressure vessel reinforced with T1000 carbon fiber and featuring an ultra-thin titanium lining for space applications is examined. Using the laminated plate theory for composite materials and the elastic-plastic theory for isotropic materials, a three-dimensional finite element model is developed. The pressure test results confirm the correctness of the finite element model. Under various internal pressure circumstances, the displacement and strain distribution of the metal liner and the laminated composite are compared and analyzed. It is shown that the composite vessel primarily deforms along the axial direction when the internal pressure is greater than the working pressure of the vessel. Only elastic deformation is present in the composite layer, but both plastic and elastic deformation are present in the ultra-thin titanium liner.

A GEOMETRIC MODEL OF IMPINGEMENT DURING DISLOCATION-PRONE ACTIVITIES IN DUAL-MOBILITY AND STANDARD ACETABULAR CUPS

Dual Mobility (DM) Total Hip Replacements (THRs), are becoming widely used but function in-vivo is not fully understood.The aim of this study was to compare the incidence of impingement of a modular dual mobility with that of a standard cup.A geometrical model of one subject's bony anatomy \[1\] was developed, a THR was implanted with the cup at a range of inclination and anteversion positions (Corail® stem, Pinnacle® cup (DePuy Synthes)). Two DM variants and one STD acetabular cup were modelled. Joint motions were taken from kinematic data of activities of daily living associated with dislocation \[2\] and walking. The occurrence of impingement was assessed for each component combination, orientation and activity. Implant-implant impingement can occur between the femoral neck and the metal or PE liner (DM or STD constructs respectively) or neck-PE mobile liner (DM only).The results comprise a colour coded matrix which sums the number of impingement events for each cup position and activity and for each implant variant.Neck-PE mobile liner impingement, occurred for both DM sizes, for all activities, and most cup placement positions indicating that the PE mobile liner is likely to move at the start of all activities including walking.For all constructs no placement positions avoided neck-metal (DM) or neck-PE liner (STD) impingementevents in all activities. The least number of events occurred at higher inclination and anteversion component positions. In addition to implant-implant impingement, some instances of bone-bone and implant-bone impingement were also observed.Consistent with DM philosophy, neck-PE mobile liner impingement and liner motion occurred for all activities including walking. Neck-liner impingement frequency was comparable between both DM sizes (metal liner) and a standard cup (PE liner).

Design, optimization, manufacture, and tests of CFRP hydraulic cylinder tube without metal liner: A bionic thorn‐tooth connection

AbstractHydraulic cylinders are widely used in rudder surface control, landing gear retraction of aircraft. The aircraft could benefit a lot on weight reduction, by the application of the carbon fiber reinforced polymer (CFPR) on the hydraulic cylinder. The design, optimization, manufacture of the CFRP hydraulic cylinder tube without metal liner is systematically studied in this article. In terms of structure design, inspired by natural thorn plants, a bionic thorn‐tooth connection structure is designed to connect CFRP and the metal end. Then the theoretical design method of thorn‐tooth is proposed. It also provides a new solution for the generic technology of CFRP‐to‐metal connection. In terms of CFRP parameters design method, an accurate mechanical model of CFRP hydraulic tube is established, the influence law of CFRP parameters on mechanical properties is explored, and the optimization method of CFRP parameters adapted to new characteristics is proposed. In terms of the manufacturing process, the split manufacturing‐combined molding process with high precision and low cost is developed to fit the characteristics of CFRP hydraulic tube without metal liner. The prototype manufactured by the proposed method has a weight reduction ratio of 62.37% while maintaining performances compared to the original metal hydraulic cylinder tube. This research will bring significant performance gains and considerable economic and environmental benefits to aircrafts.Highlights The systematic study of CFRP hydraulic tube without metal liner is presented for weight reduction. The bionic thorn‐tooth connection and its parameter design method are proposed. The CFRP parameters design method of CFRP hydraulic tube is established. A manufacturing process adapted to CFRP hydraulic tube without metal liner is developed.

Inverted-bearing reverse shoulder arthroplasty: long-term survivorship, complications, clinical, and radiological outcomes

Inverted-bearing reverse shoulder arthroplasty (IB-RSA) is characterized by a polyethylene glenosphere and a metallic humeral liner to minimize polyethylene wear and debris secondary to impingement between the humerus and glenoid neck. IB-RSA long-term survivorship, complication and revision rates, as well as clinical and radiographic outcomes have not been reported yet. This is a monocentric retrospective study on a consecutive series of 151 patients who underwent primary IB-RSA from January 2009 to September 2015 and were evaluated clinically and radiologically at the minimum 8-year follow-up. All complications and reoperations were recorded. Survivorship analysis with any revision surgery as endpoint was done using Kaplan-Meier survival curves. Seventy-eight patients (follow-up rate 51.7%) were reviewed at a mean follow-up of 10.1±1.9years. At 10years, the revision-free survival was 98.7% (95% confidence interval: 94.8-99.7). Sixteen complications (10.6%) were observed: 2 axillary nerve injuries, 2 infections, 2 glenoid loosening (which stabilized within 1 year), 2 cases of otherwise unexplained painful stiffness, 4 acromial fractures, 1 post-traumatic scapular pillar fracture, and 3 post-traumatic humeral periprosthetic fractures. Two patients were revised due to infection. No cases of late glenoid loosening and humeral loosening were observed. The revision rate was 1.3%. All the clinical scores and range of motion significantly improved at the last follow-up compared with preoperative status: final Constant score was 66.1±17.4, Subjective Shoulder Value 79.1±20.9, and the American Shoulder and Elbow Surgeons 82.2±17.7. Scapular notching was observed in 51.4% of patients: only 1 case of grade 3 notching was observed in an early glenoid subsidence case. Primary IB-RSA appears to be a safe and effective procedure and does not present specific implant-associated complications at long-term follow-up. Radiographic analysis showed that inverting the biomaterials leads to a distinct kind of notching with mainly mechanical features.

Metal artifact reduction sequence-MRI abnormalities in asymptomatic patients with dual-mobility hip prostheses.

Modular dual-mobility (DM) articulations are increasingly used during total hip arthroplasty (THA). However, concerns remain regarding the metal liner modularity. This study aims to correlate metal artifact reduction sequence (MARS)-MRI abnormalities with serum metal ion levels in patients with DM articulations. A total of 45 patients (50 hips) with a modular DM articulation were included with mean follow-up of 3.7 years (SD 1.2). Enrolled patients with an asymptomatic, primary THA and DM articulation with over two years' follow-up underwent MARS-MRI. Each patient had serum cobalt, chromium, and titanium levels drawn. Patient satisfaction, Oxford Hip Score, and Forgotten Joint Score-12 (FJS-12) were collected. Each MARS-MRI was independently reviewed by fellowship-trained musculoskeletal radiologists blinded to serum ion levels. Overall, two patients (4.4%) had abnormal periprosthetic fluid collections on MARS-MRI with cobalt levels > 3.0 μg/l. Four patients (8.9%) had MARS-MRI findings consistent with greater trochanteric bursitis, all with cobalt levels < 1.0 μg/l. A seventh patient had a periprosthetic fluid collection with normal ion levels. Of the 38 patients without MARS-MRI abnormalities, 37 (97.4%) had cobalt levels < 1.0 μg/l, while one (2.6%) had a cobalt level of 1.4 μg/l. One patient (2.2%) had a chromium level > 3.0 μg/l and a periprosthetic fluid collection. Of the 41 patients with titanium levels, five (12.2%) had titanium levels > 5.0 μg/l without associated MARS-MRI abnormalities. Periprosthetic fluid collections associated with elevated serum cobalt levels in patients with asymptomatic DM articulations occur infrequently (4.4%), but further assessment is necessary due to implant heterogeneity.

An interface tracking, finite volume code for modeling axisymmetric implosion of a rotating liquid metal liner with free surface

We present Integrated System Model-hydrodynamics (ISM-hydro)—an interface tracking, finite volume code for modeling a shaped implosion of a rotating, initially cylindrical, fluid shell (liner) with a free surface. The code is a novel implementation of the mixed Lagrangian–Eulerian approach, applied to a compressible fluid in an axisymmetric geometry described by cylindrical coordinates (r, ϕ, z). In ISM-hydro, a structured quadrilateral mesh follows fluid elements in the r-direction (radially Lagrangian) and is fixed in the z-direction (axially Eulerian). This approach accurately captures the motion of the liner's free surface, making it an interface tracking method. Using this mesh, we derive a finite volume discretization of the axisymmetric Euler equations for a rotating compressible fluid that has an exact balance of kinetic energy. An extensive comparison between ISM-hydro and the open-source software OpenFOAM is presented; results for different test cases show very good agreement in simulated implosion trajectories and flow fields. ISM-hydro is the purely hydrodynamic component of the Integrated System Model (ISM), a framework developed at General Fusion (GF) for comprehensive predictive modeling of GF's magnetized target fusion (MTF) scheme, where an imploding rotating liquid metal liner compresses a magnetized plasma target to fusion conditions. Among advantages of the code is its speed: a full implosion simulation with a coarse mesh takes on the order of one minute on a single core while preserving high accuracy. This makes ISM-hydro a valuable tool for the design optimization of GF's MTF machines.

Model-experiment comparison of quasi static loading on a composite overwrap pressure vessel (Part 2)

A methodology to develop a 3D Finite Element (FE) model of a full metal-lined Composite Overwrapped Pressure Vessel (COPV) was developed and is presented in this paper. The model is intended for prediction of the metal-composite delamination and residual dent depth developed in the metal liner as a result of quasi-static indentation loading. Cohesive elements are used to model the composite and the metal-composite interfaces. Experimental and numerical comparisons of force–displacement curves, delamination area and residual dent depth are presented. Numerical results are in good agreement to the experimental data.

Stress and Deformation Analysis of Prestressed Wound Composite Components with an Arch-Shaped Metal Liner.

The stress distribution in prestressed filament wound components plays a crucial role in determining the quality of these components during their operational lifespan. This article proposes a physical model to analyze the stress and deformation of prestressed wound composite components with arch-shaped sections. Drawing upon the principles of beam theory, we delve into the analysis of prestressed wound components with metal liners featuring arch-shaped sections. Our investigation revealed a noteworthy phenomenon termed the "additional bending moment effect" within prestressed wound components with arch-shaped sections. Furthermore, this study establishes a relationship between this additional bending moment and the external pressure. In addition, a 3D finite element (FE) model for prestressed wound components with arch-shaped sections incorporating metal liners was developed. The model's accuracy was validated through a comparison with prestressed wound experiments, showcasing an error margin of less than 2%. In comparison with prestressed wound components with circular cross-sections under identical load and dimensional parameters, it was observed that prestressed wound components with arch-shaped sections exhibit stress distributions in the arc segments akin to their circular counterparts, with differences not exceeding 5%. Notably, when the ratio of the straight segment length to the inner diameter of the arc segment inner is less than 4, the deformation on the symmetric plane of the arc segment in an arch-shaped component can be effectively considered as the summation of deformations in equivalent-sized arc and straight segments under identical loading conditions. This yields an equivalent physical model and a streamlined analysis and design methodology for describing the deformation characteristics of prestressed wound components with arch-shaped sections.

Influence of winding angles on hoop stress in composite pressure vessels: Finite element analysis

Various pressure vessels from Type I to Type IV are used to store hydrogen and compressed natural gas (CNG) at high pressures. The polymeric liner in Type IV composite pressure vessels (CPVs) does not share the load, unlike those with metallic liners (Type III); hence, the composite layers share the entire load. The winding angles play a crucial role in tailoring the pressure-bearing properties of CPVs. This study investigated the effect of fiber winding angles on the hoop stress in Type IV CPVs using finite element (FE) analysis, and the advantage of multi-angle winding was realized. Stress analysis is vital to ensure that the vessel can withstand the intended operating conditions without undergoing failure. A series of finite element analyses (FEA) was carried out using the Abaqus FE simulation software to study the behavior of an anisotropic fiber-reinforced CPV with varied winding schemes. A stress analysis was performed, and various winding schemes were compared for different cases. The hoop stress in various configurations was documented to assess and compare various winding configurations.

Shape manipulation of a rotating liquid liner imploded by arrays of pneumatic pistons: Experimental and numerical study

Shaping the inner surface of a rotating, imploding liquid metal liner as it compresses a magnetised plasma target is an important aspect of the Magnetised Target Fusion (MTF) scheme pursued by General Fusion. Reduced-order modelling has shown that the liner's inner surface shape can be manipulated during the implosion by spatially varying the amplitude and timing of pressure applied at the liner's outer surface. A sub-scale apparatus was constructed to investigate this concept, using water as the liner material. A simplified axisymmetric model of this apparatus was also developed using OpenFOAM software. Experimental pressure and rotational speed were used as inputs to numerical simulations. Very good agreement between numerical and experimental liner trajectories was obtained for a wide range of implosion parameters. Data analysis confirmed an initially cylindrical inner liner surface can be shaped and the shaped surface remains symmetrical to radial compression ratios of at least 7:1, despite driving the implosion using pneumatic piston arrays. Furthermore, experiments demonstrated suppression of Rayleigh-Taylor instability for shaped implosions by using liner rotation. This is significant, as literature only confirms this suppression for cylindrical implosions. These results increase confidence in simplified numerical modelling as a predictive tool for designing MTF machines.