Analysis of Failed Ankle Arthroplasty Components.

BACKGROUND:: Although advances in joint-replacement technology have made total ankle arthroplasty a viable treatment for end-stage arthritis, revision rates for ankle replacements are higher than in hip or knee replacements. The questions asked in this study were what can retrieved ankle devices demonstrate about ankle arthroplasty failures and how can understanding the causes of these failures inform clinical decisions for current and future ankle arthroplasty patients? METHODS:: An IRB-approved retrieval laboratory received retrieved components and surgeon-supplied reason for revision from 70 total-ankles (7 designs, including 5 currently marketed designs) from 2002 to 2018. These retrievals were rated for clinical wear and damage. Metal components were rated by method and effectiveness of fixation. Polyethylene inserts received by the laboratory 6 months or less after retrieval (n = 45) were analyzed for oxidation using Fourier transform infrared spectroscopy. Statistical analysis was performed using IBM SPSS, version 22. RESULTS:: The ankle implants were retrieved most commonly for loosening and polyethylene fracture. Loosening occurred more frequently in fixed-bearing designs (n = 18) than in the mobile-bearing designs (n = 4) and after shorter in vivo time (mean in vivo time to retrieval for loosening: fixed bearing 3.2 ± 2.1 years, mobile bearing 9.7 ± 4.5 years). Gamma-sterilized ankle inserts oxidized at a higher rate than non-gamma (EtO or gas-plasma) sterilized ankle inserts (gamma 0.29 ± 0.22/y, non-gamma 0.07 ± 0.05/y, mean difference=0.215, 95% CI 0.128-0.303, P < .001). The presence of clinical fatigue (cracking and/or delamination) of the polyethylene insert correlated with measured oxidation (Spearman rho = 0.685, P < .001). Nine inserts, all gamma-sterilized, fractured in vivo. CONCLUSIONS:: This study suggests that loosening could be more of a problem in fixed-bearing devices than in mobile bearing devices. Gamma-sterilized polyethylene inserts were found to suffer fatigue damage or fracture in vivo, resulting in the need for revision. Retrieval analysis can provide insight into implant-related reasons for revision, with the goal of understanding the implant-related causes of these failures, informing future ankle design and clinical decisions for current and future ankle arthroplasty patients. LEVEL OF EVIDENCE:: Level III, comparative series.

Contribution of micro-motion to backside wear in a fixed bearing total knee arthroplasty.

This study seeks to identify important factors related to backside wear of tibial inserts in vivo and determine an appropriate wear model for backside wear. An IRB approved database was queried for tibial inserts of a single design from one manufacturer that exhibited evidence of rotatory motion on the backside of the polyethylene. These devices were measured for volumetric wear using a previously established protocol. Features including the change in locking lip width and measurement of micro-motion marks were used to describe the motion pattern. Volumetric wear and implant characteristics were compared using linear regressions by modeling wear theories suggested by Archard and Wang to determine the most appropriate model for backside wear. The Wang model showed that duration, adjusted sliding distance, and cross-shear index accounted for approximately 58% of the volumetric wear variation while adjusted sliding distance and duration in vivo accounted for approximately 35% of the volumetric wear variation in the Archard model. Patient weight (p = 0.750), patient BMI (p = 0.680), and backside area (p = 0.784) of the tibial insert were all found to be non-significant in the Wang model. Similarly, patient weight (p = 0.233), patient BMI (p = 0.162), and backside area (p = 0.796) were found to be non-significant in the Archard model. Multidirectional micro-motion appears to contribute significantly to the wear of these components, supporting the Wang theory of cross-shear for polyethylene wear. Cross-shear of polymers on an unpolished titanium tray can lead to an increase in wear debris in the body. Care should be taken when designing locking mechanisms and tray designs. © 2016 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 34:1933-1940, 2016.

Comparison of Wear and Oxidation in Retrieved Conventional and Highly Cross-Linked UHMWPE Tibial Inserts.

Two groups of retrieved tibial inserts from one manufacturer's knee system were analyzed to evaluate the effect of a highly cross-linked bearing surface on wear and in vivo oxidation. The two groups ((1) conventional gamma-inert sterilized and (2) highly cross-linked, coupled with the same rough (Ra=0.25) Ti-6Al-4V tray) were matched with statistically similar in vivo duration and patient variables. The retrieved inserts were analyzed for ketone oxidation and wear in the form of dimensional change. The difference in oxidation rate between highly cross-linked and conventional gamma-inert sterilized inserts did not reach statistical significance. Observations suggest that the majority of wear can be accounted for by the backside interface with the rough Ti-6Al-4V tray; however, wear measured by thickness-change rate was statistically indistinguishable between the two bearing materials.

Catastrophic Failure of the Acetabular Polyethylene Liner in Ceramic-on-Polyethylene Total Hip Arthroplasty.

INTRODUCTION: Catastrophic polyethylene failure is a rare complication of ceramic-on-polyethylene total hip arthroplasty due to the favorable tribological characteristics of ceramic. Failure of the polyethylene liner can be disastrous, increasing periprosthetic osteolysis, metallosis, and risk of dislocation. Complications associated with ceramic-on-polyethylene articulations have been studied extensively, however, only few reports have described its catastrophic wear. We report such a case of complete wear of the acetabular liner in a ceramic-on-polyethylene prosthesis in a 57-year adult male. CASE REPORT: A 57-year adult male with a history of bilateral total hip arthroplasty presented to our institution with bilateral hip pain worst on the right. Range of motion was limited by pain on the right hip at the extremes of motion. Radiographs revealed severe osteolysis, heterotopic ossification, complete wear of the acetabular liner, bony impingement of the femoral greater trochanter on the acetabular rim and superior migration of the femoral head. All findings were confirmed intraoperatively. Revision of the acetabular components was performed, which successfully alleviated the patient's symptoms. CONCLUSION: Failure of the ceramic-on-polyethylene liner in our patient is due to the use of a non-cross linked polyethylene liner, a highly active lifestyle, and poor follow up. Arthroplasty surgeons should be aware of this complication especially in highly active patients with a conventional polyethylene liner and chronic hip pain.

Knee wear measured in retrievals: a polished tray reduces insert wear.

BACKGROUND: Polyethylene wear is often cited as the cause of failure of TKA. Rotating platform (RP) knees show notable surface damage on the rotating surface raising concerns about increased wear compared to fixed bearing inserts. QUESTIONS/PURPOSES: We therefore addressed the following questions: Is wear in RP inserts increased compared to that in fixed bearing inserts? Does the surface roughness of the tibial tray have a measurable impact on in vivo wear of modular knees? And does wear rate differ between posterior stabilized (PS) and cruciate retaining (CR) knees? METHODS: We compared wear in two series of retrieved knee devices: 94 RP mobile bearings with polished cobalt-chrome (CoCr) trays and 218 fixed bearings with both rough titanium (Ti) and polished CoCr trays. Minimum implantation time was 0.4 months (median, 36 months; range, 0.4-124 months) and 2 months (median, 72 months; range, 2-179 months) for the RP and fixed bearing series, respectively. RESULTS: Wear rate was lower for RP inserts than for fixed bearing inserts. Backside wear rate was lower for fixed bearing inserts mated to polished CoCr trays than for inserts from rough Ti trays. Inserts against polished trays (RP or fixed bearing) showed no increase in wear rate increase over time. Wear rate of PS knees was similar to that of CR knees. CONCLUSIONS: We found mobile bearing knees have reduced wear rate compared to fixed bearings, likely due to the polished CoCr tibial tray surface. Fixed bearing inserts in polished CoCr trays wear less than their counterparts in rough Ti trays, and the wear rate of inserts from polished CoCr trays does not appear to increase with time.

Femoral stem fracture and in vivo corrosion of retrieved modular femoral hips.

A series of 78 retrieved modular hip devices were assessed for fretting and corrosion. Damage was common at both the head-neck junction (54% showing corrosion; 88% showing fretting) and at the stem-sleeve junction (88% corrosion; 65% fretting). Corrosion correlated to in vivo duration, patient activity, and metal (vs ceramic) femoral heads but did not correlate to head carbon content. Femoral stem fatigue fracture was observed in seven retrievals; all had severe corrosion, were under increased stress, and were in vivo longer than the non-fractured cohort. This study emphasizes the potential for stem fracture when small diameter femoral stems with large offsets are used in heavy and active patients. Designs which reduce fretting and corrosion in modular implants is warranted as patients demand longer lasting implants.

Metal transfer on a ceramic head with a single rim contact.

A notable feature of retrieved ceramic-on-ceramic hips is metal transfer on the femoral head, which is an important alteration of the bearing surface. This report documents metal transfer streaks on a ceramic femoral head resulting from discrete subluxations, which occurred intraoperatively during reduction and stability testing. An important implication is that metal transfer can occur whenever a femoral head is reduced into the liner during surgery or from in vivo subluxation/dislocation. If a ceramic liner is recessed below a raised metal rim, care should be taken to prevent head-to-rim contact during intraoperative reductions and stability testing. If metal transfer occurs during final surgical reduction of the hip, its presence may remain undetected, and detrimental effects are present from the time of surgery.

Gamma-irradiation sterilization in an inert environment: a partial solution.

BACKGROUND: In the mid to late 1990 s, to sterilize UHMWPE bearings, manufacturers changed from gamma-irradiation-in-air (gamma-air) sterilization, which initiated oxidation leading to bearing fatigue, to gamma-irradiation sterilization in an inert environment (gamma-inert). The change to gamma-inert sterilization reportedly prevented shelf oxidation before implantation but not in vivo oxidation. QUESTIONS/PURPOSES: We asked: (1) Has the change to gamma-inert sterilization prevented shelf oxidation that led to early in vivo fatigue damage in gamma-air-sterilized tibial inserts? And (2) has the change to gamma-inert sterilization prevented the occurrence of fatigue secondary to in vivo oxidation? METHODS: We rated 183 retrieved gamma-air- and 175 retrieved gamma-inert-sterilized tibial inserts for clinical fatigue damage and analyzed 132 gamma-air- and 174 gamma-inert-sterilized tibial inserts for oxidation by Fourier transform infrared spectroscopy. RESULTS: Oxidation led to decreased mechanical properties in shelf-aged gamma-air-sterilized tibial inserts. Barrier packaging prevented shelf oxidation in gamma-inert-sterilized tibial inserts. Gamma-air- and gamma-inert-sterilized inserts oxidized in vivo. Fatigue damage (delamination) occurred more frequently in inserts retrieved after longer time in vivo. Longer in vivo time correlated with higher oxidation and more accumulated cycles of use. CONCLUSIONS: Published oxidation projections suggest gamma-inert-sterilized tibial inserts would reach the critical oxidation for the onset of fatigue after 11 to 14 years in vivo. These retrievals appear to follow the projected oxidation trends. Frequency of fatigue damage increased with increasing oxidation. CLINICAL RELEVANCE: Fatigue of tibial inserts becomes more likely, especially in active patients, after more than a decade of good clinical performance.

Evaluating the suitability of highly cross-linked and remelted materials for use in posterior stabilized knees.

Posterior stabilized (PS) knee designs are a popular choice for cruciate sacrificing knee arthroplasty procedures. The introduction of PS inserts fabricated from highly cross-linked and remelted Ultra High Molecular Weight Polyethylene (UHMWPE) has recently generated concern as these materials have been shown to possess reduced mechanical properties. This study investigated whether highly cross-linked and remelted UHMWPE material (referred to as XRP) can be expected to perform similarly to historical gamma-air polyethylene, which has suffered few reported incidences of tibial post failure. Never-implanted gamma-air PS tibial inserts shelf-aged 14 years were examined and compared to XRP materials. Evaluation of oxidation levels, impact toughness, and fatigue strength demonstrated never-implanted gamma-air PS tibial inserts to possess nonuniform mechanical properties. Despite severe oxidation along the exterior of gamma-air tibial posts, comparatively low oxidation levels at the center of the tibial posts corresponded to sufficiently high mechanical properties. XRP material (75 kGy) showed superior impact toughness over shelf aged gamma-air material; however, tibial post fatigue testing demonstrated XRP material (100 kGy) to be less resistant to fatigue failure than historical gamma-air material. Results from this study indicate that XRP materials (100 kGy) may demonstrate an inferior resistance to tibial post failure than historical polyethylene.

Clinical wear measurement on low contact stress rotating platform knee bearings.

Whereas fixed-bearing total knee arthroplasty (TKA) designs secure the polyethylene bearing to the tibial tray, mobile-bearing TKAs allow the bearing to move relative to the tray. This study evaluated wear performance of the rotational articulation of the Low Contact Stress Rotating Platform mobile-bearing TKA (DePuy, Warsaw, Ind) by analyzing 100 retrievals. All retrieved bearings showed rotation surface damage, but severity of the damage did not correlate with duration. Rotation surface damage appeared to be caused by contaminant particles, which produced curvilinear scratches that were longer than the normal rotational excursion of the knee. Wear measurement indicated that wear was relatively uniform, long-term wear rates were low (mean, 54 mm(3)/y for durations >2 years) and decreased with longer duration, and damaged appearance did not correspond to high wear.

Rim cracking of the cross-linked longevity polyethylene acetabular liner after total hip arthroplasty.

BACKGROUND: Studies have suggested that cross-linked polyethylene bearings reduce wear rates from 40% to 100% compared with conventional polyethylene. However, the reduced mechanical properties of highly cross-linked polyethylene have the potential to be a limiting factor in device performance. We reviewed a series of retrieved acetabular liners with a fracture of the superior rim to assess the factors that played a role in their failure. METHODS: Four Longevity acetabular bearings, which had been retrieved from two patients after seven to twenty-seven months in vivo, were visually examined for clinical damage, were assessed with use of Fourier transform infrared spectroscopy to determine the level of oxidation, and were analyzed for mechanical properties and fracture surface characterization. Control data were obtained from never-implanted devices and from global reference ultrahigh molecular weight polyethylene bar stock as an industry calibration material. RESULTS: All four retrieved liners demonstrated articular surface wear modes, which in most cases were rated as moderate, and none were rated as severe. All showed cracking or rim failure of the liner at the superior aspect along the groove in the polyethylene that engages the locking ring of the shell. The retrieved liners had no measurable oxidation, and the mechanical properties were comparable with those of never-implanted material. CONCLUSIONS: There was no notable in vivo degradation of the retrieved liners. Important factors related to failure appear to be thin polyethylene at the cup rim, relatively vertical cup alignment, and the material properties of the highly cross-linked polyethylene that are decreased relative to conventional polyethylene. The critical dimension with respect to rim failure in modular liners appears to be the minimum thickness at the equatorial region.

Evaluation of oxidation and fatigue damage of retrieved crossfire polyethylene acetabular cups.

BACKGROUND: Crossfire cross-linked polyethylene is produced differently from other cross-linked polyethylene materials; a below-melt-temperature annealing process is used with the goal of avoiding compromised mechanical properties. The present study was performed to evaluate retrieved Crossfire acetabular cups to determine whether they had oxidized and to what extent oxidation might have influenced their clinical performance. METHODS: Eleven acetabular cups were received at retrieval and a twelfth acetabular cup was received two years post-retrieval over a period of four years. None were retrieved because of polyethylene wear or fatigue. The cups had been in vivo from 0.1 to 5.3 years. Each was examined visually, clinical fatigue damage was rated, and oxidation was measured with use of Fourier transform infrared spectroscopy. RESULTS: The cups exhibited oxidation that varied with its location on the cup: the oxidation value was generally low on the articular surface but more than an order of magnitude higher value on the rim. Maximum rim oxidation correlated significantly with the time in vivo (Spearman rho = 0.734, p = 0.010). Oxidation was identified visually by a white band in thin sections on the rim of seven of the cups and on the articular surface of one of these seven cups. Six of the seven cups also exhibited clinical fatigue damage. Eight of the twelve cups exhibited evidence of impingement or dislocation. CONCLUSIONS: Acetabular cups made of Crossfire polyethylene oxidized to a measurable degree. The oxidation-related reduction of polyethylene mechanical properties was sufficient to allow the fatigue damage seen in these retrieved cups.

In vivo oxidation of gamma-barrier-sterilized ultra-high-molecular-weight polyethylene bearings.

gamma-Barrier packaging is shown to be effective in preventing oxidation of polyethylene during shelf storage and in addressing the problem of early fatigue failure seen in gamma-air-sterilized bearings with long shelf-storage before implantation. The series of gamma-barrier retrievals studied suggests that oxidation occurs in the body via the same mechanism as seen in gamma-air-sterilized bearings. A critical oxidation level is identified above which polyethylene bearings are susceptible to fatigue damage after sufficient cycles of use. Although critical oxidation was not reached in the majority of the retrieved gamma-barrier bearings studied, in vivo oxidation appears to follow an exponential increase with time. The result of in vivo oxidation is expected to be loss of mechanical properties, and susceptibility of polyethylene bearings to eventual fatigue failure.

Fatigue fracture of a proximally modular, distally tapered fluted implant with diaphyseal fixation.

We report and analyze the causes of a fracture in a proximally modular, distally tapered fluted MP stem in a 48-year-old woman (168 cm, 67 kg) with severe proximal bone deficiency. Evidence of fatigue failure with striations initiated laterally was observed in the laser etching of the tensile aspect of the prosthesis. However, metallurgical analysis suggested that laser engraving did not alter the microstructure of the stem. Stress due to the absence of proximal femoral bone support may have been sufficiently high to put this particular stem at risk for fatigue fracture. This important complication should be addressed when choosing this therapeutic option in cases with substantial proximal femoral bone loss. Strut allograft support should be recommended in such cases.

Analysis of wear asymmetry in a series of 94 retrieved polyethylene tibial bearings.

Knee joint kinematics is the focus of a significant amount of experimental study for the purpose of knee prosthesis design and for testing the wear of current and prospective bearing materials. This study reports the wear assessment of a series of 94 explanted tibial bearings of various designs and manufacturers and focuses on the extent to which clinical wear is symmetric in the medial-lateral aspect, or is indicative of a systematic asymmetry that would be informative to the design and testing of knee prostheses or surgical practice. Wear assessment of the series of retrievals indicates that, statistically, there was more clinical wear on the medial side. Patterns of wear varied greatly among individual knees; a majority showed very similar extents of wear on the medial and lateral sides, however there were cases with significantly more wear on one condylar articulation than the other. Evidence of edge loading, whereby the femoral component articulates at the margin of the tibial bearing, was common. It was seen most frequently in the central zone of the medial condylar area, and, like the overall wear, edge loading was significantly more frequent on the medial side of bearings. Total bearing wear was seen to generally increase with time over the 208 months of in vivo duration covered by the retrievals in the study. The medial-lateral asymmetry of the wear does not appear to be significantly dependent on duration, however.

Differences in articular track area of posterior-stabilized and cruciate-retaining retrieved total knee implants.

Press-fit condylar total knee arthroplasties removed at revision surgery from 27 knees were examined. Fourteen of the implants were posterior-stabilized press-fit condylar systems and 13 were cruciate-retaining press-fit condylar systems. The articular track areas were examined using a digital camera and manual measurements. Findings revealed the track area in posterior-stabilized implants (93%) was larger than in cruciate-retaining implants (59%). Mean posterior distance ratio of the articular track from the posterior limit of the polyethylene was 2% (.08 cm) for posterior-stabilized implants versus 23% (.97 cm) for cruciate-retaining implants. No differences in wear rating were noted. The pattern of articular contact in cruciate-retaining knees demonstrated little migration of the femoral contact surface across the tibial polyethylene plateau.

Hip arthroscopy: surgical approach, positioning, and distraction.

The hip is the most deeply recessed joint in the body making it difficult to access arthroscopically. However, for the patient with a symptomatic loose body or labral tear open techniques are less advantageous. It is for this reason that, however difficult, minimally-invasive approaches to the hip have been developed. Meticulous attention to proper positioning and portal placement is paramount for safe and successful arthroscopy of the hip. The current authors will review the seminal features of positioning and minimally-invasive surgical approaches to the hip.