Release of zirconia nanoparticles at the metal stem-bone cement interface in implant loosening of total hip replacements.

In a previous failure analysis performed on femoral components of cemented total hip replacements, we determined high volumes of abraded bone cement. Here, we describe the topography of the polished surface of polymethyl methacrylate (PMMA) bone cement containing zirconia radiopacifier, analyzed by scanning electron microscopy and vertical scanning interferometry. Zirconia spikes protruded about 300nm from the PMMA matrix, with pits of former crystal deposition measuring about 400nm in depth. We deduced that the characteristically mulberry-shaped agglomerates of zirconia crystals are ground and truncated into flat surfaces and finally torn out of the PMMA matrix. Additionally, evaluation of in vitro PMMA-on-PMMA articulation confirmed that crystal agglomerations of zirconia were exposed to grain pullout, fatigue, and abrasion. In great quantities, micron-sized PMMA wear and zirconia nanoparticles accumulate in the cement-bone interface and capsular tissues, thereby contributing to osteolysis. Dissemination of nanoparticles to distant lymph nodes and organs of storage has been reported. As sufficient information is lacking, foreign body reactions to accumulated nanosized zirconia in places of long-term storage should be investigated. STATEMENT OF SIGNIFICANCE: The production of wear particles of PMMA bone cement in the interface to joint replacement devices, presents a local challenge. The presence of zirconia particles results in frustrated digestion attempts by macrophages, liberation of inflammatory mediators, and necrosis leading to aseptic inflammation and osteolyses. Attempts to minimize wear of articulating joints reduced the attention to the deterioration of cement cuffs. We therefore investigated polished surfaces of retrieved cuffs to demonstrate their morphology and to measure surface roughness. Industrially admixed agglomerates of the radiopacifier are abraded to micron and nano-meter sized particles. The dissemination of zirconia particles in the reticulo-endothelial system to storage organs is a possible burden. Research to replace the actual contrast media by non-particulate material deserves more attention.

Interface abrasion between rough surface femoral stems and PMMA cement results in extreme wear volumes--a retrieval study and failure analysis.

During the loosening cascade of cemented rough femoral stems, the destruction of the mantle and the production of cement and metal wear debris occur after the loss of constraint at the interface. Two-dimensional (2D) measurements (light microscopy based morphometry on fragments of mantles and vertical scanning interferometry of femoral stems) permitted mathematical 3D-extrapolations to estimate the wear volumes. Fragments of the cement mantles available lost volumes from 0.85 mm(3) to 494.10 mm(3) (median amount of bone cement wear = 178,426 mg). The harder metal surfaces lost between 1.459 mm(3) and 5.688 mm(3) of material (the median amount of metal wear per surface = 1.504 mg/100 mm(2)). Compared to the loss of material due to the fretting of stems, the abrasion of metal, and cement in defective cement mantles produced wear volumes sufficiently high to induce osteolysis. Though the design of the femoral stem and the handling of bone cement do not represent contemporary design and clinical practice, respectively, an extremely high number of joint replacements still in daily use may be impacted by this study because of possible predicted failures. Once the processes of fragmentation, abrasion, and osteolysis have been realized, the time until revision surgery should not be unduly prolonged.