Backside polyethylene wear in reverse shoulder arthroplasty.

BACKGROUND: Aseptic loosening from implant-associated osteolysis in reverse shoulder arthroplasty (RSA) may contribute to premature implant failure. Although articular side polyethylene (PE) damage has been well documented in the literature, no studies to date have investigated backside wear in RSA. The aims of this investigation were to (1) document and compare the damage between the backside and articular surface in explanted RSA components, (2) assess whether certain quadrants have a greater propensity for damage, and (3) report the most common mode(s) of backside PE damage. METHODS: Twenty-one RSA humeral liners retrieved during revision procedures between 2005 and 2014 were included for analysis. The mean time between implantation and extraction was 16 months (10 days-88 months). Diagnoses at the time of revision included dislocation (10), infection (4), mechanical failure (3), loosening (2), and unknown (2). Liners were examined under light microscopy (×10-30 magnification) and damage on the articular and backside of the liner surface was graded using the modified Hood score. The location and damage modality were compared between the articular side and backside of the implant. RESULTS: Damage was noted on the articular surfaces of all 21 liners and on the backside surface of 20 liners. The total damage in all the quadrants was higher on the articular surface than on the backside of the component, with a mean difference in total quadrant damage scores of 11.74 ± 3.53 (P < .001). There was no difference in damage among the quadrants on the backside (P = .44) or the articular surface (P = .08). The articular side exhibited greater scratching, abrasion, and surface deformation than the backside (P < .001). CONCLUSIONS: This short-term retrieval study demonstrated that backside PE damage occurs on the humeral component of RSA implants. There was greater damage to the articular side of the liner but wear to the backside was present in almost all liners. The clinical importance of backside wear in RSA and its overall contribution to PE particulate disease and osteolysis needs further investigation.

Do Well-functioning THAs Retrieved at Autopsy Exhibit Evidence of Fretting and Corrosion?

BACKGROUND: Our understanding of fretting and corrosion at head-neck junctions in modular THAs in vivo is based largely on the analysis of retrieved implants removed for various diagnoses. Little is known about the condition of head-neck tapers in well-functioning THAs. QUESTIONS/PURPOSES: Regarding a cohort of well-functioning autopsy-retrieved modular THAs, we asked: (1) Does trunnion geometry or femoral head material affect the pull-off force of the femoral head? (2) Is there a relationship between trunnion damage and length of implantation time, head diameter, and neck length? (3) Does visual damage scoring accurately determine the presence or absence of corrosion on cobalt-chrome trunnions? METHODS: Sixty-six femoral stems and engaged femoral heads were retrieved at autopsy from 53 patients at Anderson Orthopaedic Research Institute from 1998 to 2014. Ten stems were excluded for low stem design group size or insufficient head-stem clearance for pull-off testing, leaving a cohort of 56 THAs with a median implantation time of 10 years (range, 1-24 years). The femoral stems included three cobalt-chrome (CoCr) designs from a single manufacturer with either a 12/14 or 14/16 trunnion design (N = 36 and 20, respectively) mated with alumina or CoCr heads (N = 13 and 43, respectively). The force required to pull off the femoral heads was measured using a uniaxial load frame according to ASTM F2009-00. Mating surfaces were visually examined to assess the presence and severity of fretting and corrosion using a modified Goldberg scoring system. Three 12/14 trunnions of similar implantation lengths and varied damage scores were selected for imaging with a scanning electron microscope (SEM) and energy dispersive x-ray analysis (EDAX) to confirm the absence or presence of corrosion damage. RESULTS: No difference was seen in pull-off force between groups based on trunnion geometry and head material (median [range], alumina-12/14: 3127 [2320-6992] N, alumina-14/16: 2670 [1095-7919] N, CoCr-12/14: 2255 [1332-5939] N, CoCr-14/16: 2812 [1655-4246] N; p = 0.132). A positive correlation was found between damage score and length of implantation (ρ = 0.543, p < 0.001). However, no correlation between damage score and either head diameter or neck length was found (ρ = -0.012, p = 0.930 and ρ < 0.001, p = 0.995, respectively). In all, 39 of 56 specimens demonstrated no fretting or corrosion, and 16 specimens had mild damage scores. One specimen demonstrated severe corrosion without visual evidence of fretting. The presence of intergranular corrosion on this trunnion was determined by SEM imaging and EDAX. The absence of corrosion products on two trunnions with no observed damage was confirmed. CONCLUSIONS: This study found little evidence of fretting and corrosion in a cohort of well-functioning CoCr-CoCr and alumina-CoCr head-neck couples. Further studies are necessary to characterize fretting and corrosion at head-neck junctions of well-functioning implants of other designs and manufacturers. CLINICAL RELEVANCE: The results from this study suggest that patients with well-functioning THAs using polyethylene bearing surfaces with alumina or CoCr heads appear to be at low risk for trunnion corrosion for the specific CoCr alloy stems and trunnion geometries analyzed here.

Polyethylene Wear Increases in Liners Articulating With Scratched Oxidized Zirconium Femoral Heads.

BACKGROUND: Oxidized zirconium (OxZr) femoral heads were introduced in hip arthroplasty to reduce wear of the polyethylene compared with metallic heads and to reduce fracture risk compared with ceramic heads. Severe scratches have been reported on OxZr heads in patients undergoing revision for instability, but whether these scratches contribute to increased acetabular polyethylene wear remains unclear. QUESTIONS/PURPOSES: (1) How is the polyethylene of the acetabular liner affected by damage on the opposing OxZr head? (2) How does damage to the head affect the degree of polyethylene wear? METHODS: We assessed damage and deformation on all retrieved highly crosslinked liners that had articulated against OxZr heads collected at one institution between 2006 and 2013. Two observers used a visual subjective scoring system to assess polyethylene damage on the surface of the 42 retrieved liners. Polyethylene components were also laser scanned to measure dimensional changes to the liner. These outcomes were compared with the severity of scratching on the surface of the articulating OxZr head. We also used a 12-station hip simulator to measure wear over five million cycles (MCs) of pristine liners articulating against nine retrieved OxZr heads with varying degrees of scratching representing a spectrum of little to severe damage and three retrieved ceramic heads with severe metal transfer. RESULTS: Seventeen of the OxZr heads showed severe damage, of which 14 heads had been revised for dislocation. The retrieved liners that had articulated with these heads had greater damage scores for abrasion (mean score 0.4 versus 1.6; p = 0.008) and embedded debris (mean score 0.4 versus 1.4; p = 0.006) compared with liners that had articulated with less damaged heads. Four severely damaged OxZr heads wore at a higher rate than the others in the study with weight loss of 37.7 mg, 30.0 mg, 14.4 mg, and 2.6 mg after the first MC and a steady increase through testing to 5 MCs. Conversely, neither OxZr heads with less damage nor ceramic heads with severe metal transfer produced appreciable wear. CONCLUSIONS: Surface scratching of OxZr heads from recurrent dislocation and reduction maneuvers leads to increased wear of the crosslinked polyethylene used as a bearing surface. CLINICAL RELEVANCE: Patients in whom such instability occurs in the presence of an OxZr head should be followed closely for the possibility of more severe wear.

Ceramic Bearings with Titanium Adapter Sleeves Implanted During Revision Hip Arthroplasty Show Minimal Fretting or Corrosion: a Retrieval Analysis.

BACKGROUND: The BIOLOX® option system, consisting of a BIOLOX® delta ceramic femoral head with a titanium alloy adapter sleeve, is being increasingly utilized in revision hip arthroplasty. The sleeve protects the ceramic head from fracture and improper motion about the stem trunnion when a damaged trunnion is encountered at revision surgery. Corrosion and fretting due to metal-metal contact at the taper region of hip prosthesis create the potential of causing periprosthetic osteolysis and adverse local tissue reactions. QUESTIONS/PURPOSES: The objective of this study was to identify the type and extent of damage to retrieved sleeves and ceramic heads to determine their in vivo performance. METHODS: Twenty-four ceramic heads with titanium alloy sleeves were examined. The articular and taper surfaces for each ceramic head were assessed for metal transfer using a subjective grading system. All surfaces of the 24 titanium sleeves and stem trunnions (only available for 7 of 24 cases) were assessed for corrosion and fretting using an established grading system. Scanning electron microscopy and energy dispersive X-ray analysis were conducted on representative sample of sleeves. RESULTS: Fretting and corrosion were higher at the inner surface of the taper sleeve than the outer sleeve. Mean fretting scores at the inner taper and outer taper sleeve surfaces were 1.8 and 1.2, respectively. The mean corrosion score at the inner taper surface was 1.8; no corrosion was observed on the outer surface of any taper sleeve. SEM and EDS analyses provided further indications of low levels of damage. CONCLUSION: Fretting and corrosion were less severe than previously reported for conventional THA metal-metal taper connections, indicating that a ceramic head and titanium sleeve is a safe alternative in revision THA.

Frondlike Synovitis on MRI and Correlation With Polyethylene Surface Damage of Total Knee Arthroplasty.

OBJECTIVE: The purpose of this study is to determine the association between polyethylene surface damage and the severity of frondlike hypertrophied synovitis, joint distention, capsular thickness, and osteolysis on MRI compared with other patient factors. Another goal of this study is to ascertain the interobserver reliability in MRI evaluation of synovitis. MATERIALS AND METHODS: MR images of 61 patients who had undergone revision total knee arthroplasty (TKA) were retrospectively reviewed. The two MRI reviewers were blinded to clinical and retrieval data. The retrieved polyethylene tibial inserts were graded to determine the severity of surface damage. The association of MRI features with surface damage was assessed using Spearman correlation coefficients and multiple linear regression. Interobserver reliability was assessed using the kappa statistic. RESULTS: Correlations were moderate between the surface damage score and MRI synovitis severity (r = 0.46; p < 0.001) and joint distention (r = 0.41; p = 0.001). Multiple linear regression showed that the MRI synovitis score (p = 0.045), male sex (p = 0.007), body mass index (p = 0.041), and the time since implantation (p < 0.0001) predicted the surface damage score. Substantial interobserver agreement was shown for MRI grading of synovitis (κ = 0.72; 95% CI, 0.65-0.80). CONCLUSION: The magnitude of frondlike hypertrophied synovitis on MRI is significantly associated with polyethylene surface damage in patients who undergo revision TKA. The finding of severe frondlike synovitis on MR images of patients with TKA should raise the possibility of polyethylene surface damage. However, time since implantation is a stronger predictor of surface damage.

Polyethylene Damage Increases With Varus Implant Alignment in Posterior-stabilized and Constrained Condylar Knee Arthroplasty.

BACKGROUND: Implant malalignment in primary TKA has been reported to increase stresses placed on the bearing surfaces of implant components. We used a longitudinally maintained registry coupled with an implant retrieval program to consider whether preoperative, postoperative, or prerevision malalignment was associated with increased risk of revision surgery after TKA. QUESTIONS/PURPOSES: (1) What is the relative polyethylene damage on medial and lateral compartments of the tibial plateaus from revised TKAs? (2) Does coronal TKA alignment affect implant performance, such that TKAs aligned in varus are predisposed to experience increased polyethylene damage? (3) Does TKA alignment differ between postoperative and prerevision radiographs, and if so, what does this difference suggest about the mechanical contact load placed on a knee with a TKA? METHODS: Between 2007 and 2012, we performed 18,065 primary TKAs at our institution. By March 2016, 178 of those TKAs (1%) were revised at our center at least 2 years after primary surgery at our institution. Eighteen of those TKAs were excluded from this analysis because the tibial insert was not explanted during revision surgery, and four more were excluded because the inserts were lost or returned to the patient before the study was initiated, leaving 156 retrieved polyethylene tibial inserts (in 153 patients) revised at greater than 2 years after the primary TKA for this retrospective study. Patients who underwent revision surgery elsewhere were not considered here, since this study depended on having retrieved components. Polyethylene damage modes of burnishing, pitting, scratching, delamination, surface deformation, abrasion, and third-body debris were subjectively graded on a scale of 0 to 3 to reflect the extent and severity of each damage mode. On preoperative, postoperative, and prerevision radiographs, overall alignment, femoral alignment, and tibial alignment in the coronal plane were measured according to the protocol recommended by the Knee Society. RESULTS: Knees with more overall varus alignment after TKA had increased total damage on the retrieved tibial inserts (Spearman's rank correlation coefficients of -0.3 [95% CI, -0.4 to -0.1; p = 0.001]). We also found revised TKAs tended to drift back into greater varus before revision surgery, with a mean (SD) of 3.6° ± 4.0° valgus for postoperative alignment compared with 1.7° ± 6.4° prerevision (p = 0.04). CONCLUSIONS: Despite surgical efforts to achieve neutral mechanical alignment, remaining varus alignment places an increased contact load on the polyethylene articular surfaces. The drift toward further varus alignment postoperatively is consistent with the knee adduction moment remaining high after surgery. CLINICAL RELEVANCE: While we found a predisposition toward recurrence of the preoperative varus deformity, we did not find increased medial as opposed to lateral polyethylene damage, which may be explained by the curve-on-curve toroidal design of the articulating surfaces of the TKA implants in this study.

Retrieval Analysis of Neck-Stem Coupling in Modular Hip Prostheses.

BACKGROUND: Dual-taper modular stems have suffered from high revision rates caused by adverse local tissue reactions secondary to fretting and corrosion. We compared the fretting and corrosion behavior of a group of modular neck designs to that of a design that had been recalled for risks associated with fretting and corrosion at the modular neck junction. METHODS: We previously analyzed fretting and corrosion on 60 retrieved Rejuvenate modular neck-stem implants. Here we compare those results to results from 26 retrieved implants from 7 other modular neck designs. For the 26 additional cases, histology slides of tissue collected at revision were reviewed and graded for aseptic lymphocyte-dominated vasculitis-associated lesion (ALVAL). Multivariate analyses were performed to assess differences in fretting and corrosion, adjusting for confounding factors (eg, length of implantation). RESULTS: The Rejuvenate design had higher damage and corrosion scores than the other 7 designs (P < .01). Histologic samples from the recalled design were 20 times more likely to show ALVAL than samples from the other designs (P < .01). Mixed metal couples had higher fretting (P < .01) and corrosion (P = .02) scores than non-mixed metal couples. CONCLUSION: Fretting and corrosion occurred on all modular neck-stem retrievals regardless of design. However, mixed metal couples suffered more corrosion than homogenous couples. This may be due to the lower modulus of the titanium alloy used for the stem, allowing for increased metal transfer and surface damage when loaded against a cobalt alloy modular neck, which in turn could account for the higher ALVAL and corrosion scores. Due to increased corrosion risk with mixed metals and increased neck fracture risk with non-mixed metal stem and necks, we suggest that clinicians avoid implantation of modular neck-stem systems.

Fretting and Corrosion at the Backside of Modular Cobalt Chromium Acetabular Inserts: A Retrieval Analysis.

BACKGROUND: Adverse local tissue reaction formation has been suggested to occur with the Modular Dual Mobility (MDM) acetabular design. Few reports in the literature have evaluated fretting and corrosion damage between the acetabular shell and modular metal inserts in this modular system. We evaluated a series of 18 retrieved cobalt chromium MDM inserts for evidence of fretting and corrosion. METHODS: We assessed the backsides of 18 MDM components for evidence of fretting and corrosion in polar and taper regions based on previously established methods. We collected and assessed 30 similarly designed modular inserts retrieved from metal-on-metal (MoM) total hip arthroplasties as a control. RESULTS: No specific pattern of fretting or corrosion was identified on the MDM inserts. Both fretting and corrosion were significantly greater in the MoM cohort than the MDM cohort, driven by higher fretting and corrosion scores in the engaged taper region of the MoM inserts. CONCLUSION: MoM components demonstrated more fretting and corrosion than MDM designs, specifically at the taper region, likely driven by differences in the taper engagement mechanism and geometry among the insert designs. The lack of significant fretting and corrosion observed in the MDM inserts are inconsistent with recent claims that this interface may produce clinically significant metallosis and adverse local tissue reactions.

Does Achieving High Flexion Increase Polyethylene Damage in Posterior-Stabilized Knees? A Retrieval Study.

BACKGROUND: Increased range of motion to higher degrees of flexion following total knee arthroplasty has been postulated to increase implant damage and revision rates, even in designs modified to accommodate high flexion. METHODS: We examined posterior-stabilized and high-flexion retrieved tibial inserts to look for differences in polyethylene surface damage with light microscopy and 3D deviation with laser scanning between inserts from patients who achieved a high degree of flexion (≥120° postoperatively) and inserts from patients who did not reach a high degree of flexion. RESULTS: No differences were found in damage scores on the articular and backside surfaces, except for abrasion in the posterior articular regions, or in 3D deviations between patients who reached a high degree of flexion and patients who did not. These results were independent of the reason for revision. CONCLUSION: In our series, reaching a high degree of flexion did not influence surface damage or 3D deviation of the polyethylene inserts.

Spontaneous Fractures of a Modern Modular Uncemented Femoral Stem.

BACKGROUND: Femoral stem fracture following total hip arthroplasty is an uncommon event that requires immediate revision surgery. QUESTIONS/PURPOSES: We report on four patients who experienced stem fractures of one design and a review of the US Food and Drug Administration adverse event reports on this design. METHODS: Fracture surfaces of four EMPERION™ (Smith & Nephew, Memphis, TN) femoral stems were analyzed under optical and scanning electron microscopy. A search of the FDA's Manufacturer and User Facility Device Experience (MAUDE) that reports on all EMPERION™ adverse events was completed. RESULTS: Fracture surfaces exhibited characteristics consistent with a fatigue fracture mechanism. Sixteen MAUDE reports claimed stem fracture or breakage of EMPERION™ stems. CONCLUSION: The four cases of EMPERION™ stem fractures were likely driven by small stem diameter, high offset, and high patient weight. Modular stem-sleeve femoral systems are susceptible to fatigue failure under high stress and should only be used in appropriate patients, whom are not considered obese.

Flexural Rigidity, Taper Angle, and Contact Length Affect Fretting of the Femoral Stem Trunnion in Total Hip Arthroplasty.

BACKGROUND: Modularity at the head-neck junction in total hip arthroplasty allows for intraoperative adjustments but may be a source of metallic debris. We determined how flexural rigidity, taper angle, contact length, and lever arm affect fretting and corrosion at this junction. METHODS: A total of 77 metal-on-polyethylene total hip arthroplasties retrieved over a 10-year period at a single institution were obtained. Head tapers and stem trunnions were graded for fretting and corrosion. RESULTS: Stem fretting was inversely related to rigidity and taper angle, while positively correlated to contact length. Head fretting and head and stem corrosion were not associated with any of these parameters. CONCLUSION: Design and assembly factors at the modular head-neck connection affected stem fretting among the retrieved components, suggesting that these parameters are important to consider when choosing a modular system.

Assessment of Damage on a Dual Mobility Acetabular System.

BACKGROUND: Dual mobility designs were introduced to increase stability and reduce the risk of dislocation, both being common reasons for surgical revision after total hip arthroplasty. The in vivo behavior of dual mobility constructs remains unclear, and to our knowledge, no data have been published describing in vivo surface damage to the polyethylene bearing surfaces. METHODS: We used surface damage assessed on the inner and outer polyethylene bearing surfaces in 33 short-term retrieved dual mobility liners as evidence of relative motion at the 2 bearings. A lever out test was performed to determine the force required for dislocation of the cobalt-chromium femoral head from the polyethylene liner. RESULTS: Both bearings showed damage; however, the inner polyethylene bearings had higher damage scores, lower prevalence of remaining machining marks, and higher incidence of concentric wear, all consistent with more motion at the inner polyethylene bearing. The inner polyethylene bearings also had a higher occurrence of embedded titanium debris. The damage sustained in vivo was insufficient to lead to intraprosthetic dislocation in any of the retrieved components. Lever out tests of 12 retrievals had a mean dislocation load of 261 ± 52 N, which was unrelated to the length of implantation. CONCLUSION: Our short-term retrieval data of 33 highly cross-linked polyethylene dual mobility components suggest that although motion occurs at both bearing articulations, the motion of the femoral head against the inner polyethylene bearing dominates. Although damage was not severe enough to lead to intraprosthetic dislocation, failure may occur long term and should be assessed in future studies.

Posterior Stabilized Polyethylene Inserts in Total Knee Arthroplasty: A Retrieval Study Comparing Conventional to High-Flexion Designs.

BACKGROUND: High-flex (HF) total knee arthroplasties are modified posterior-stabilized (PS) implants designed to accommodate greater flexion. METHODS: We examined differences between HF and PS retrieved tibial inserts with regard to polyethylene surface damage. Twenty HF inserts from each of 3 manufacturers were matched using patient demographics with 20 PS inserts from the same manufacturers. Ranges of motion between matched patients were not different. RESULTS: Based on subjective damage scores, no differences were detected between HF and PS groups. Differences were found, however, among manufacturers, consistent with design approaches taken for PS and HF implants. CONCLUSION: In our series, high flexion did not influence damage, although this was likely influenced by the fact that few HF patients in our study had larger range of motions than their PS counterparts.