ABSTRACT
Cracking of intramedullary nails, starting at the proximal end of the partial slot and propagating in a circumferential direction, has been observed. These partial cracks are relatively frequent, although full failures are very rare and do not disturb fracture healing. Coining is a cold-working process used to improve the endurance of structures with residual compressive stresses generated by plastic deformation. The influence of coining was investigated to evaluate its practical value in controlling these fatigue cracks. Bending and torsional tests were performed on high frequency machines. Coined zones of different shapes and depths were examined, comparing the elapsed number of load cycles with crack initiation. The results showed that the endurance of coined nails was improved by factors of approximately 10 and 5 in bending and torsion, respectively. This increase in fatigue life corresponds to a more than 50% larger dynamic load after a million cycles. Variations in coining shape and depth did not yield any significant differences.
