Steady-state Wear Rate Research Articles

Microstructural and wear properties of iron slag reinforced aluminum alloy (LM30) based composite prepared through a stir casting method

Aluminum alloys are widely used in various industries due to their as low density, high strength-to-weight ratio, and good corrosion resistance. However, their wear resistance is often inadequate for certain applications. Utilization of industrial waste materials, such as iron slag, as reinforcement in aluminum alloy matrix composites offers a sustainable approach to material development and waste management. The utilization of industrial waste materials for aluminum alloy matrix composite fabrication offers a waste utilization to material development. The loading of this reinforcement varied from 0 to 15 wt.% and different particle size range (220-140, 140-70, and 70-0 µm). A microscopic analysis indicated that the iron slag particles are spread uniformly inside the metallic matrix. There is also a reduction in the size of primary silicon, as well as morphological changes (acicular to globular shape). The wear behavior was calculated using a pin-on-disk wear set up in accordance with ASTM G99 standard. The composites were employed to dry sliding wear test under various operating conditions such as applied pressure (0.2–1.4 MPa), and sliding distance (0–3000 m). The 15F composite outperformed all other composite samples in terms of wear rate under all working conditions. When compared to the base alloy, it demonstrated a remarkable 67% drop in steady state wear rate. The enhancements in wear performance for the 15F composite were attributed to the effects of Fe slag reinforcement. The inclusion of iron slag particles induced strong interfacial bonding between matrix and reinforcement particles improving the durability of the mechanical mixed layer developed during relative motion. Importantly, the wear rate parameters of the 15F composite were similar to those of the brake drum material used in commercial applications. This emphasizes the composite suitability for usage in a variety of automobile components.

Minimum 7-year results of cementless total hip arthroplasty with vitamin E-diffused and 2-methacryloyloxyethyl phosphorylcholine-grafted highly cross-linked polyethylene.

The purpose of this study was to evaluate the mid-term clinical results and polyethylene wear of vitamin E-diffused highly cross-linked polyethylene (HXLPE) and 2-methacryloyloxyethyl phosphorylcholine (MPC)-grafted HXLPE in cementless total hip arthroplasty (THA). Thirty-four THAs with vitamin E-diffused HXLPE (VEPE) and 32-mm cobalt-chromium head, and 116 THAs with MPC-grafted HXLPE and 32-mm alumina head were evaluated. The Merle d'Aubigné and Postel scores were administered. Kaplan-Meier survivorship was analyzed. Annual radiographs were analyzed using computerized method and linear steady-state wear rate was measured. The mean duration of follow-up was 9 years (range, 7-11 years) in VEPE group and 8 years (range, 7-10 years) in MPC group. The mean Merle d'Aubigné and Postel scores improved postoperatively in both groups. Kaplan-Meier survivorship with endpoint of revision was 100% (95% confidence interval, 100%-100%) in VEPE group and 98.3% (95% confidence interval, 93.4%-99.6%) in MPC group at 10 years (P = .44). The mean steady-state wear rate was 0.007 mm/year in VEPE group and 0.006 mm/year in MPC group (P = .60). The clinical results of both groups were good and wear rates of both liners were very low.

Influence of Artificially Altered Engine Oil on Tribofilm Formation and Wear Behaviour of Grey Cast Cylinder Liners

This work investigates the influence of altered engine oil on the tribological performance, focusing in particular on wear and interconnected tribofilm formation. For this purpose, Zinc dialkyldithiophosphate (ZDDP) additivated engine oils of different degradation levels, produced in an artificial oil alteration process, were used in tribometer tests with a nitride steel piston ring against a grey cast iron cylinder liner model contact. Parameters were chosen to simulate the boundary and mixed lubrication regime typical for the top dead centre conditions of an internal combustion engine of a passenger car. Wear of the cylinder liner specimens was continuously monitored during the tribometer tests by the radio-isotope concentration (RIC) method, and tribofilms were posteriorly investigated by X-ray photoelectron spectroscopy (XPS). The results clearly show that the steady-state wear rates for experiments with altered lubricants were significantly lower than for the experiments with fresh lubricants. XPS analysis on the formed tribofilms revealed a decrease in sulphide and an increase in sulphate states for altered oils evaluated at 120 °C oil temperature, correlating with a decrease in steady-state wear rate. This finding emphasizes the role of sulphate species in the tribofilm formation process and its anti-wear capabilities, in contrast to the sulphide species and the (poly-)phosphate species, as outlined in most of the ZDDP literature. Moreover, the RIC signal that represents the amount of wear in the engine oil showed a decrease over time for specific altered lubricants and test conditions. These “negative” trends in the wear signal are remarkable and have been identified as an incorporation of wear particles from the lubricant into the tribofilm. This finding is supported by XPS results that detected an iron-oxide layer with a remarkably similar quantity within the tribofilm on the surface. Based on these findings, an assessment of the minimum film formation rate and particle incorporation rate was achieved, which is an important basis for adequate tribofilm formation and wear models.

In vivo creep and wear performance of vitamin-E-diffused highly crosslinked polyethylene in total hip arthroplasty.

An acetabular liner thickness of around 6mm remains the "gold standard" in total hip arthroplasty. Some surgeons have been recommending the use of the thickest possible liner because contact stress and strain in articulating surfaces decrease with increasing the wall thickness. The purpose of this study was to determine whether in vivo creep and wear performance could be enhanced using a thicker liner over the standard thickness in vitamin-E-diffused highly crosslinked polyethylene (HXLPE). One hundred and twenty-two hips were allocated to age-matched, sex-matched, and body mass index-matched two subgroups implanted either with a 6.8- or 8.9-mm-thick vitamin-E-diffused HXLPE liner against 28-mm cobalt-chrome femoral head, and followed-up for 7years. Linear and volumetric penetration of femoral head into the liners attributed to creep and wear were analyzed for each group. Compressive creep strain generated at the initial 6months was significantly larger in the 6.8-mm group (2.6%) than in the 8.9-mm group (2.2%). The linear steady-state wear observed after 2years was 0.0019 and 0.0015mm/year, whereas the volumetric steady-state wear was 0.54 and 0.45 mm3/years in the 6.8- and 8.9-mm-thick groups, respectively. Although less strain in the thicker group resulted in a slightly less wear, it did not reach significant differences in the steady-state wear rates between the groups. No clinical significance for using a thicker liner over the standard thickness (6.8mm → 8.9mm) was confirmed in the vitamin-E-diffused HXLPE according to the 7-year follow-up. The wear rates for both thicknesses were very low enough to prevent osteolysis, and no mechanical failure was observed at any follow-up interval. Nevertheless, since the significantly higher strain was seen in the thinner liner, further follow-up is needed to compare the longer term wear and the incidence of osteolysis and component fracture.

A Ten-Year Radiostereometric Analysis of Polyethylene Wear Between Oxidized Zirconium and Cobalt Chrome Articulations in Total Hip Arthroplasty.

Oxidized zirconium (OxZi) femoral heads combine the decreased abrasive properties of ceramics with the toughness of metal alloys to lower wear and increase the durability of total hip arthroplasty. The purpose of this study was to compare the 10-year polyethylene wear rates between OxZi/XLPE and cobalt chrome (CoCr)/XLPE articulations. A radiostereometric analysis (RSA) was performed on two cohorts of 23 patients who underwent total hip arthroplasty using either OxZi/XLPE or CoCr/XLPE at a minimum of 10-year follow-up. Cohorts were matched for age, gender, body mass index (BMI), and diagnosis. Polyethylene wear was measured using RSA to determine total and steady-state wear rates for both cohorts. Preoperative and postoperative patient-reported outcome measures (SF12, HHS, and Western Ontario and McMaster Universities Arthritis Index scores) were compared. The mean total head penetration rate was found to be statistically different between the entire cohorts (OxZi 0.048±0.021 mm/y, CoCr 0.035±0.017 mm/y, P= .02) but not when 28-mm heads only (OxZi 0.045±0.016 mm/y, CoCr 0.034±0.017 mm/y, P= .066) were directly compared. The mean steady-state wear rate was not significantly different between the entire cohorts (OxZi 0.031±0.021 mm/y, CoCr 0.024±0.019 mm/y, P= .24) or 28-mm head cohorts (OxZi 0.028±0.019 mm/y, CoCr 0.024±0.019 mm/y, P= .574). Outcome measures showed no statistical difference except for the Harris Hip Score where the OxZi cohort demonstrated higher median scores. Using RSA to evaluate the 10-year in-vivo head penetration, there was no statistically significant difference in steady-state wear rates between OxZi and CoCr articulations. Both bearing combinations demonstrated wear rates well below the threshold for osteolysis.

Wear assessment of a Ti–6Al–4V motion-preserving porous artificial-cervical-joint fabricated by SLM after surface carburization

Adjacent segment degenerative diseases are a major clinical concern for anterior cervical corpectomy with fusion surgery. In this study, a hybrid motion-preserving cervical prosthesis consists of two articulating joints and one porous fusion body is designed to provide motion ability and reduce the occurrence of degenerative diseases. The hybrid design is fabricated from Ti–6Al–4V (TC4) alloy using selective laser melting (SLM) technology. After carburization pretreatment, two types of bearing couple SLM-TC4 self-mating and SLM-TC4/UHMWPE were studied in terms of lubrication regime, contact mechanics and wear performance. According to the ISO 18192-1 standard, five million cycles (Mc) of in vitro spine simulator wear tests were conducted in bovine serum lubricated condition.Hamrock-Dawson minimum lubrication film thickness analysis stated that both bearing was likely under boundary lubrication only, with extensive surface asperities contact. And, the contact stress encountered during in vitro condition was not enough to cause surface fatigue failure of any bearing couple. In term of wear performance, the obtained steady state wear rates were 0.160 ± 0.004 mm3/Mc for SLM-TC4 self-mating and 8.57 ± 0.06 mm3/Mc for SLM-TC4/UHMWPE bearing couples, respectively. According to these outcomes, SLM-TC4 self-mating couple was more promising for the articulating joint bearing design.For SLM-TC4 self-mating couple, the initial wear mechanism was abrasion with potential third-body abrasion wear. As the wear cycle proceeding, the TiC cermet layer was gradually damaged and exposed the local bare metal. Under this circumstance, material loss was consisted of abrasion wear, adhesion wear, and tribo-corrosion. In comparison, the wear mechanism of SLM-TC4/UHMWPE bearing was always abrasion-adhesion of UHMWPE. The surface of UHMWPE socket was severely plowed by the hard micro bulge of the TiC layer, and material loss and plastic deformation occurred only on the UHMWPE socket. In conclusion, carburization pre-treatment causes a hard TiC cermet layer formation on the SLM-TC4, which enhance its hardness and protect underling material from corrosion damage. The thickness and quality of the TiC layer directly affect the longevity of the joint prosthesis in vivo.

Ultralow Wear Self-Mated PTFE Composites

Remarkably low wear rates were observed in PTFE–PEEK and polytetrafluoroethylene (PTFE)-alpha-alumina composites when evaluated in a “self-mated” configuration, where a polymer pin is slid against a polymer countersample of the same composition. Each composite was tested in a controlled humidity environment on a linearly reciprocating tribometer on two different countersamples: a polymer countersample (self-mated) and a stainless steel countersample for comparison. For all the self-mated PTFE–PEEK composites [polyether ether ketone (PEEK) wt % 10, 20, 30, 40, and 50], the average friction coefficient was reduced, and the steady-state and total specific wear rates were improved when compared to testing against stainless steel. Self-mated PTFE–PEEK (wt % 10–40) achieved ultralow wear rates on the order of 10–9 mm3/Nm and friction coefficients of 0.08–0.14. When compared with samples slid against stainless steel, IR spectroscopy of the sliding surface showed that the self-mated PTFE–PEEK composites accumulate more PEEK at the sliding interface and more expression of a tribochemical carboxylate species, which have been linked with ultralow wear PTFE materials. The PTFE composites slid on steel rely on the formation of transfer films for ultralow wear performance. This is achieved by unidirectional increasing surface energy gradients from the polymer pin to the steel substrate, which dominate the transport and wear of PTFE composites slid on steel. However, the self-mated ultralow wear PTFE-based composites rely only on the formation and stability of tribofilms that consist of tribochemically altered PTFE with new carboxylate end groups as well as accumulated filler (i.e., PEEK or alumina). These films have self-regulating, minimal differences in surface energy. The close match of these low-energy surfaces contributes to low friction and ultralow wear. The self-mated PEEK-filled PTFE outperforms the alumina-filled PTFE primarily because of the ease at which PEEK accumulates at the surface. Additionally, the reinforcement and anchoring of the surface is better for a polymer blend than a particle-reinforced composite.

Maintaining low friction coefficient and ultralow wear in metal-filled PTFE composites

Many reinforcing fillers (particles, fibers, and platelets) can reduce the high wear rate of polytetrafluoroethylene (PTFE) (K∼10−4 to 10−3mm3/Nm) by 10–1000 times. However, certain α-alumina particles can produce up to 10,000 times lower wear rate when composited with PTFE (K∼1.3 × 10−7- 6.7 × 10−8 mm3/Nm). This ultralow wear behavior was attributed to two mechanisms: tribofilm generation and tribochemistry. However, while reducing the wear rate of PTFE, α-Al2O3 can also increase its friction coefficient up to two times (μ∼ 0.1 vs 0.2–0.25). This study revealed that the friction coefficient of PTFE-Cr against Brass 260 counterbody is up to three times lower than the ultralow wear PTFE α-alumina against 304 Stainless Steel (μ = 0.08–0.12 vs μ = 0.2–0.25) with up to 200 times lower steady-state wear rate (K∼1.4-34 × 10−9 mm3/Nm) than PTFE α-alumina against 304 SS (K∼6.7-13 × 10−8), and ∼3 × 105 times lower than unfilled PTFE. PTFE-Ti (μ = 0.09, Kss= 2.9 × 10−8 mm3/Nm) and PTFE-Mn (μ = 0.12, Kss= 1.2 × 10−8 mm3/Nm) against Brass 260 also performed better than PTFE-α-Al2O3 against 304 SS both in reducing wear rate and friction coefficient. The tribofilms created by the PTFE-Cr, PTFE-Mn, and PTFE-Ti composites were evaluated using Scanning White Light Interferometry (SWLI) and Infrared (IR) Spectroscopy. These analyses showed that these composites created thin (500–1500 nm) films on the Brass 260 counterbody and their worn surfaces exhibited new chemical groups (carboxylate salts, hydroxyl groups, and acetate ions). These new chemical groups signal the formation of bonds between the PTFE matrix, filler particles, and the metal counterbody, which protects both the composite and counterbody from wear.

Long-term outcome of primary total hip arthroplasty with cementless bioactive glass ceramic bottom-coated implants and highly cross-linked polyethylene: A minimum 10-year analysis

BackgroundCementless glass ceramics containing apatite and wollastonite (AW-GC) bottom-coated titanium hip implants were developed; early excellent clinical and radiographic results have been reported previously. This study aimed to investigate the long-term clinical and radiographic outcomes in detail, and the wear rate of HXLPE. MethodsWe retrospectively evaluated 99 patients (117 hips) between November 2001 and December 2007. The survival rate was estimated using the Kaplan–Meier method. Hip joint function was evaluated using the Japanese Orthopaedic Association (JOA) score. The extent of radiographic signs was determined from the radiographs performed at the last follow-up. Polyethylene wear was measured using Martell's Hip Analysis Suite. We assessed the possible factors affecting the steady-state linear wear rate. ResultsThe mean follow-up period was 14.8 ± 2.1 (10–18.6) years. The mean JOA score improved to 88.7 ± 9.4 (59–100) at the final follow-up from 47.8 ± 12.5 (17–76) before surgery. The overall survival rate with the end point of all-cause revision and wear-related revision was 99% and 100% respectively. There was no osteolysis or loosening of either the acetabular or femoral component. All hips were classified as having bone ingrowth fixation. The mean steady-state wear rate was 0.008 ± 0.025 mm/year. We found no significant correlation between the wear rate and age, body weight, body mass index, cup inclination and femoral head size. ConclusionThe combination of AW-GC bottom-coated implants and HXLPE showed excellent implant survival and wear resistance for 15 years.

Vitamin E highly cross-linked polyethylene reduces mid-term wear in primary total hip replacement: a meta-analysis and systematic review of randomized clinical trials using radiostereometric analysis.

Vitamin E incorporation into highly cross-linked polyethylene (HXLPE) has been introduced to improve wear resistance, and vitamin E incorporated HXLPE (VEPE) has been used in total hip arthroplasty.The aim of this meta-analysis was to investigate the wear properties of VEPE in clinical practice by synthesizing the data provided in randomized clinical trials.The effects on implant stability, functional outcomes and revision rate of VEPE were also compared with those of HXPLE or ultra-high molecular weight polyethylene (UHMWPE).Literature searches were conducted on 1 January 2020 using MEDLINE, EMBASE, Cochrane and ClinicalTrials.gov databases. Randomized controlled trials (RCTs) comparing the aforementioned parameters between VEPE and standard HXPLE/UHMWPE liners were included.Methodological quality and the bias of the included studies were analysed. Meta-analyses were performed using the Review Manager software.Nine RCTs met the eligibility criteria and were included. At early and mid-term follow-up, the vertical penetration and the total penetration of the femoral head were both significantly reduced in the VEPE group. The steady state wear rate of the VEPE group was also remarkably lower.However, at two-year follow-up, significantly increased cup migration was observed in the VEPE group. Moreover, the mid-term clinical outcomes of the VEPE group were worse, while the total revision rates between the two groups were not significantly different.The limited number of included studies may compromise our conclusion regarding clinical outcomes of the VEPE bearing surface. More RCTs with longer follow-up periods are needed to further investigate the effects of VEPE in total hip arthroplasty. Cite this article: EFORT Open Rev 2021;6:759-770. DOI: 10.1302/2058-5241.6.200072

Does the use of the largest possible metal head increase the wear of vitamin E-doped cross-linked polyethylene? Two-year results from a randomized controlled trial.

We aimed to investigate if the use of the largest possible cobalt-chromium head articulating with polyethylene acetabular inserts would increase the in vivo wear rate in total hip arthroplasty. In a single-blinded randomized controlled trial, 96 patients (43 females), at a median age of 63 years (interquartile range (IQR) 57 to 69), were allocated to receive either the largest possible modular femoral head (36 mm to 44 mm) in the thinnest possible insert or a standard 32 mm head. All patients received a vitamin E-doped cross-linked polyethylene insert and a cobalt-chromium head. The primary outcome was proximal head penetration measured with radiostereometric analysis (RSA) at two years. Secondary outcomes were volumetric wear, periacetabular radiolucencies, and patient-reported outcomes. At two years, 44 patients in each group were available for RSA assessment. The median total two-year proximal head penetration was -0.02 mm (IQR -0.09 to 0.07; p = 0.548) for the largest possible head and -0.01 mm (IQR -0.07 to 0.10; p = 0.525) for 32 mm heads. Their difference was not statistically significant (p = 0.323). Neither group demonstrated a bedding-in period. The median steady-state volumetric wear rates were 6.1 mm3/year (IQR -59 to 57) and 3.5 mm3/year (-21 to 34) respectively, and did not differ between the groups (p = 0.848). There were no statistically significant differences in periacetabular radiolucencies or patient-reported outcomes. The use of the largest possible metal head did not increase vitamin E-doped cross-linked polyethylene wear compared with 32 mm heads at two years. Linear wear was negligible and volumetric wear rates were very low in both head size groups. There was a tendency towards higher values of volumetric wear in large heads that warrants longer-term evaluation before any definite conclusions about the association between head size and wear can be drawn. Cite this article: Bone Joint J2021;103-B(7):1206-1214.

Correction to: Short‑term clinical and radiographic outcomes of total hip arthroplasty with PMPC‑grafted highly cross‑linked polyethylene liners against 32‑mm femoral heads

A correction to this paper has been published: https://doi.org/10.1007/s10047-021-01258-4

Tribological Properties of Polytetrafluoroethylene Improved by Incorporation of Fluorinated Graphene with Various Fluorine/Carbon Ratios Under Dry Sliding Condition

Fluorinated graphene (FG) with various fluorine/carbon (F/C) ratios and graphene (G) employed as additions were incorporated into the polytetrafluoroethylene (PTFE) matrix aiming to improve the tribological properties of this self-lubricating polymer. The friction coefficients and wear rates of PTFE-based composites were tested under dry sliding condition using a ball-on-disc configuration. The performances of self-lubricity and wear resistance for four fabricated FG/PTFE composites were superior to those of G/PTFE composite, attributable to the specific surface area and chemical composition of FG sheets with various F/C ratios. Among them, the FG/PTFE composite with filler (F/C ≈ 0.5) loading of 5 wt% exhibited the best tribological property, i.e., the lowest friction coefficient (0.131) and the smallest steady-state wear rate (9.20 × 10–16 m3/Nm). This can be attributed to the formation of uniform and complete transfer film on the friction interface via the tribochemical reactions.

Short-term clinical and radiographic outcomes of total hip arthroplasty with PMPC-grafted highly cross-linked polyethylene liners against 32-mm femoral heads

We evaluated the clinical and radiographic outcomes of femoral head penetration and total hip arthroplasties with untreated and poly (2-methacryloyloxyethyl phosphorylcholine) (PMPC)-grafted highly cross-linked polyethylene (HXLPE) acetabular liners against 26-, 28-, and 32-mm cobalt–chromium alloy femoral heads 3 years after the index surgery. Three combinations of the articulating surfaces were evaluated in the present study: untreated or PMPC-grafted HXLPE liner against 26- or 28-mm femoral heads (n = 16, 24) [control (26 or 28 mm) and PMPC (26 or 28 mm)] and PMPC-grafted HXLPE liner against 32-mm femoral heads (n = 64) [PMPC (32 mm)]. The clinical outcomes improved at 3 years postoperatively for the groups. No periprosthetic osteolysis or acetabular component migration was detected, and no revision surgery was performed among the groups. The steady-state wear rate of the PMPC (26 or 28 mm) group (0.021 mm/year) was lower than that of the control (26 or 28 mm) group (− 0.015 mm/year); the steady-state wear was under the clinical threshold. In contrast, the steady-state wear rate of the PMPC (32 mm) group (-0.006 mm/year) showed no significant difference when compared to that of the PMPC (26 or 28 mm) group (p < 0.01). The results obtained in the present study clearly demonstrate that PMPC-grafting onto an HXLPE surface improved the wear resistance of acetabular liners, even when coupled with larger femoral heads. Although further follow-up evaluations are required, PMPC-grafted HXLPE acetabular liners may be a promising approach to extend the longevity of artificial joints.

Thirteen-year results of cementless total hip arthroplasty with zirconia heads on highly cross-linked polyethylene

Objectives Zirconia ceramic was introduced for femoral heads because of its mechanical strength and fracture toughness. Highly cross-linked polyethylene has been shown to achieve wear reduction compared to conventional polyethylene. The purpose of this study was to investigate the long-term results of cementless total hip arthroplasty with zirconia femoral heads on highly cross-linked polyethylene. Methods Radiographic measurements of two-dimensional femoral head penetration into the polyethylene were performed with a computerized method (PolyWare) in 93 hips at a mean follow-up of 13 years. The steady-state wear rates were measured based on the radiographs from the first year after surgery to the final follow-up. Results The mean Merle d’Aubigné and Postel score had improved significantly from 10.9 points preoperatively to 15.3 postoperatively (p < 0.001). Osteolysis was not found around the implant, and no zirconia heads had fractures. The total head penetration rate was 0.04 mm/year, and the steady-state wear rate was 0.02 mm/year. Kaplan–Meier survivorship with the endpoint of revision was 97% (95% confidence interval [CI], 92% to 99%) at 10 years. Conclusion Zirconia on highly cross-linked polyethylene demonstrated extremely low wear properties at long-term follow-up.

Minimum 10-Year Follow-Up of Cementless Total Hip Arthroplasty With a 32-mm Cobalt-Chromium Head on Highly Cross-Linked Polyethylene and a Tapered, Fiber Metal Proximally Coated Femoral Stem

BackgroundThe clinical and radiographic results of cementless total hip arthroplasty using a 32-mm cobalt-chromium head on remelted highly cross-linked polyethylene (HXLPE) and a tapered, fiber metal proximally coated femoral stem were evaluated at a mean follow-up of 12 years. MethodsA total of 57 cementless total hip arthroplasties using remelted HXLPE combined with a 32-mm cobalt-chromium head, and a tapered, fiber metal proximally coated femoral stem were performed from October 2004 to December 2006. Clinical evaluation was performed using the Merle d’Aubigné and Postel scoring system. Standardized anteroposterior and lateral radiographs of the pelvis and femur without weight-bearing were analyzed. Radiographic measurements of two-dimensional femoral head penetration into the polyethylene were performed with a computerized method. The steady-state wear rates were measured based on the radiographs from the first year after surgery to the final follow-up. ResultsThe mean Merle d’Aubigné and Postel score improved significantly from 10.7 points preoperatively to 15.6 postoperatively (P < .001). No osteolysis was found around the implant. Stem fixation in all cases showed stable bone ingrowth. Third-degree stress shielding was found in 46% of all stems. The total head penetration rate was 0.05 mm/y, and the steady-state wear rate was 0.01 mm/y. The Kaplan–Meier survivorship with the end point of revision was 95% (95% confidence interval, 85%-98%) at 12 years. ConclusionA 32-mm cobalt-chromium head on remelted HXLPE demonstrated low wear properties, and a tapered, fiber metal proximally coated femoral stem showed good results at long-term follow-up.

Micro-structure and tribological behaviors of magnetron sputtered WS x /Fe/a-C/Fe multi-layer films with various Fe layer thicknesses

ABSTRACT The WS x /Fe/a-C/Fe multi-layer films with various Fe layer thicknesses were prepared by using magnetron sputtering and alternate deposition of WS x , Fe, and a-C layers on the silicon substrates. The morphology, micro-structure, and composition of the films were characterized by scanning electron microscope, energy dispersive spectroscopy, electron probe micro-analyzer, X-ray diffraction, and X-ray photoelectron spectroscopy. The mechanical and tribological properties of the fabricated films were evaluated by using nano-indenter, film stress tester, scratch tester, and ball-on-disk tribotester. According to the obtained results, all the multi-layer films revealed a featureless micro-structure with a smooth and dense surface. As the thickness of Fe layer increased, the S/W ratio of the films was decreased from 1.38 to 1.16, the hardness, elastic modulus, and adhesion of the films were gradually improved. Both the steady-state friction coefficient and wear rate were declined first and, then, enhanced. The film with the Fe-layer thickness of 4 nm exhibited the highest hardness (10.6 GPa) and adhesion (38.0 N); whereas, film with the Fe-layer thickness of 2 nm showed the best tribological performance with a steady-state friction coefficient of 0.218 and wear rate of 1.63 × 10−15m3 N−1 m−1.

Experimental investigation of debris entrapment in annular contacts

In wearing contacts, a part of the wear debris is trapped between the surfaces, creating a wear debris bed. Many researchers report such beds providing a degree of protection against further wear. It was hypothesized, that in an annular contact, the level of debris entrapment increases with the width of the annulus resulting in decrease in wear. To test this hypothesis, two series of experiments using EN1A steel and 6082T6 aluminium alloy annuli, measuring 1, 2 and 4 mm wide were carried out. When steel was used, there was no clear correlation between ring width and total mass loss or steady-state wear rate. When aluminium was used, wear decreased with the ring width according to both metrics. This behaviour appears to correlate with worn surface roughness, suggesting worn surface roughness to be a parameter controlling debris entrapment.

Results of primary THA using 36 mm femoral heads on first-generation highly cross-linked polyethylene in patients less than 60 years of age: Minimum 10-year follow-ups.

Long-term results of total hip arthroplasty (THA) using highly cross-linked polyethylene (HXLPE) and metal femoral head with more than 10 years of follow-up have already been reported. However, most studies included results with a head size of 28 mm that could affect wear rates. The aim of this study was to evaluate the results of 36-mm metallic femoral heads on first-generation HXLPE in patients less than 60 years of age with a minimum follow-up of 10 years. Retrospective analysis included 54 cases from 47 patients. The mean age at the time of surgery was 47.22 years and the mean follow-up period was 131.04 months. Porous-coated cementless acetabular cups (Trilolgy®; Zimmer Inc., Warsaw, Indiana, USA) and HXLPE acetabular liners (Longevity®; Zimmer Inc.) were used for all cases. Acetabular cup abduction angles, anteversion angles, and wear rates of liner were measured using polyWare pro 3D distal version 5.10. The average modified Harris hip score at the final follow-up was 88.48 (range 80-96). Average Merle d'Aubigne and Postel score was 15.57 (range 14-18). There was no acetabular cup or femoral stem failing due to aseptic loosening. The average steady-state wear rate determined using radiographs taken at 1 year postoperatively and at the latest follow-up was 0.053 ± 0.025 mm/year. There were no statistically significant differences in liner wear rate with respect to age, variety of the femoral stem, or liner thickness. Results of THA with 36-mm metallic femoral heads on first-generation HXLPE in patients less than 60 years of age were satisfactory.

Fifteen-Year Results of Total Hip Arthroplasty With Cobalt-Chromium Femoral Heads on Highly Cross-Linked Polyethylene in Patients 50 Years and Less

BackgroundHighly cross-linked polyethylene (HXLPE) is the most commonly used bearing surface in total hip arthroplasty (THA) because of its superior wear properties, but long-term results in young patients are limited. Mid-term survivorship has been promising; however, polyethylene wear rates and need for revision surgeries remain a concern in this population. The purpose of our study is to investigate polyethylene wear rates, implant survivorship, wear-related revisions, and patient-reported outcomes in a young patient cohort at 15-year follow-up. MethodsWe performed a retrospective study of a prospective longitudinal cohort of 82 consecutive patients (89 hips) who underwent primary THA with an HXLPE acetabular liner and a cobalt-chromium femoral head. The mean age at the time of surgery for the cohort was 38.8 years (range 12-50). All patients received HXLPE liners with a cementless acetabular component coupled with a cobalt-chrome femoral head through a posterior approach with a cementless femoral component. All components were from a single manufacturer. We recorded University of California, Los Angeles Activity, and modified Harris Hip Scores. Wear calculations were made using the Martell Hip Analysis Suite (Version 8.0.4.3). ResultsAt average 15 years (range 13.1-18.5), there was a revision-free survivorship of 97.8% in our HXLPE group with no wear-related revisions. We observed a linear wear rate of 0.0185 mm/y (standard deviation 0.05) after accounting for a 1-year bedding-in period. The volumetric wear rate was found to be 12.80 mm3/y (standard deviation 22.69). These numbers are registered as clinically undetectable and are comparable to steady state wear rates in the same cohort of patients at earlier time points. We found no radiographic changes concerning osteolysis. We observed excellent patient-reported outcomes at this time point with improvements in modified Harris Hip Scores (35.3 [22.5], P < .0001) and University of California, Los Angeles Activity Scores (median 6.0, P < .0001). ConclusionAt 15-year follow-up, we demonstrated that HXLPE bearings in this young cohort had excellent wear properties, maintained superior clinical improvements, and underwent no wear-related revision operations. The HXLPE and cobalt-chrome bearing couple continues to be extremely effective 15 years after primary THA in patients less than 50 years. Level of EvidenceIV.