Reduction of wear in total hip replacement prostheses by amorphous diamond coatings.

Wear-debris-induced periprosthetic bone loss and aseptic loosening is regarded as the main long-term problem of total hip replacements (THRs). In this study the amount of wear debris from articulating surfaces of THRs was reduced so as to be close to negligible by the use of high-quality amorphous diamond (AD) coatings deposited by pulsed plasma arc techniques. The wear rates determined in a commercial hip simulator for 15 million walking cycles (corresponding to about 15 years of clinical use) in serum lubrication were even 1,000,000 times lower than the clinical values for conventional THRs (polyethylene-metal or metal-metal pairs). Elimination of wear debris and good biomechanical performance should provide a substantial improvement of the clinical longevity of the THRs.

Tantalum as a buffer layer in diamond-like carbon coated artificial hip joints.

The acid resistance of tantalum coated and uncoated human hip joint prostheses was studied with commercial CrCoMo acetabular cups. The samples were exposed to 10% HCl solution and the quantities of dissolved Cr, Co, and Mo were measured with proton-induced X-ray emission (PIXE). The absolute quantities were obtained with the use of Cr and Se solution standards. Tantalum coatings (thicknesses 4-6 microm) were prepared in vacuum with magnetron sputtering. Tantalum coating decreased the corrosion rate by a factor of 10(6). As a spinoff from recent wear tests on artificial hip joints it was shown that tantalum has excellent mechanical properties as an intermediate layer of diamond-like carbon (DLC) coatings. When tantalum was tested together with DLC on three metal-on-metal hip joint pairs in a hip simulator, no observable defects occurred during 15 million walking cycles with a periodic 50-300-kg load (Paul curve).