Continuous synthesis of high-entropy alloy nanoparticles by in-flight alloying of elemental metals.

High-entropy alloy (HEA) nanoparticles (NPs) exhibit unusual combinations of functional properties. However, their scalable synthesis remains a significant challenge requiring extreme fabrication conditions. Metal salts are often employed as precursors because of their low decomposition temperatures, yet contain potential impurities. Here, we propose an ultrafast (< 100 ms), one-step method that enables the continuous synthesis of HEA NPs directly from elemental metal powders via in-flight alloying. A high-temperature plasma jet ( > 5000 K) is employed for rapid heating/cooling (103 - 105 K s-1), and demonstrates the synthesis of CrFeCoNiMo HEA NPs ( ~ 50 nm) at a high rate approaching 35 g h-1 with a conversion efficiency of 42%. Our thermofluid simulation reveals that the properties of HEA NPs can be tailored by the plasma gas which affects the thermal history of NPs. The HEA NPs demonstrate an excellent light absorption of > 96% over a wide spectrum, representing great potential for photothermal conversion of solar energy at large scales. Our work shows that the thermal plasma process developed could provide a promising route towards industrial scale production of HEA NPs.

Effects of hip implant modular neck material and assembly method on fatigue life and distraction force.

Hip implant neck fractures and adverse tissue reactions associated with fretting-corrosion damage at modular interfaces are a major source of concern. Therefore, there is an urgent clinical need to develop accurate in vitro test procedures to better understand, predict and prevent in vivo implant failures. This study aimed to simulate in vivo fatigue fracture and distraction of modular necks in an in vitro setting, and to assess the effects of neck material (Ti6Al4V vs. CoCrMo) and assembly method (hand vs. impact) on the fatigue life and distraction of the necks. Fatigue tests were performed on the cementless PROFEMUR® Total Hip Modular Neck System under two different loads and number of cycles: 2.3 kN for 5 million cycles, and 7.0 kN for 1.3 million cycles. The developed in vitro simulation setup successfully reproduced in vivo modular neck fracture mode and location. Neck failure occurred at the neck-stem taper and the fracture ran from the distal lateral neck surface to the proximal medial entry point of the neck into the stem. None of the necks failed under the 2.3 kN load. However, all hand-assembled Ti6Al4V necks failed under the 7.0 kN load. In contrast, none of the hand-assembled CoCrMo necks and impact-assembled necks (Ti6Al4V or CoCrMo) failed under this higher load. In conclusion, Ti6Al4V necks were more susceptible to fatigue failure than CoCrMo necks. In addition, impact assembly substantially improved the fatigue life of Ti6Al4V necks and also led to overall higher distraction forces for both neck materials. Overall, this study shows that the material and assembly method can affect the fatigue strength of modular necks. Finally, improper implant assembly during surgery may result in diminished modular neck survivability and increased failure rates. © 2016 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 35:2023-2030, 2017.

In vitro assessment of strength, fatigue durability, and disassembly of Ti6Al4V and CoCrMo necks in modular total hip replacements.

Modularity in total hip replacement offers advantages with regard to biomechanical adjustments and leg lengths. Recently, modular femoral necks were introduced as an added advantage to head modularity permitting further adjustments in femoral version as well as offset and ease of revision. Currently, most necks are made of Ti6Al4V for which cases of in vivo fractures and inseparable neck-stem junctions have been reported. Therefore, we investigated CoCrMo head-Ti6Al4V stem hip replacements with necks made of CoCrMo as an alternative to Ti6Al4V. We compared the two materials with respect to (1) compressive load bearing capacity; (2) fatigue durability; and (3) component distraction. We performed in vitro fatigue-pull-off, microscopy, fatigue durability and compression investigations. The CoCrMo neck showed a load bearing capacity of 18 kN, 38% higher than 13 kN for the Ti6Al4V neck. A fatigue load of 11.2 kN for 1 million cycle failure was achieved with CoCrMo translating into nearly 1000 times longer fatigue life compared to Ti6Al4V necks. The neck-stem distraction force showed large statistical variation and was similar for both neck materials. Overall, the results suggest a superiority of CoCrMo over Ti6Al4V as neck material with regard to mechanical behavior. However, the corrosion behavior was not appropriately assessed and necessitates additional investigations.

Retrieval analysis and in vitro assessment of strength, durability, and distraction of a modular total hip replacement.

We investigated a commercial Co-Cr-alloy head--Ti6Al4V alloy neck and Ti6Al4V stem modular total hip replacement. We assessed the distraction forces after in vitro cycling in bovine serum, fatigue durability, fretting corrosion damage, and load bearing capacity of new implants using fatigue-corrosion, pull-off, scanning electron microscopy, fatigue and compression investigations. In addition, we studied corrosion, fretting damage, and distraction forces on retrievals. For both retrievals and in vitro test samples, the neck-stem interface required the higher distraction force as compared with the head-neck interface. One of 12 retrievals showed strong fretting corrosion at the neck-stem interface which resulted in a high disassembly force of about 16 kN. For in vitro test samples, the neck-stem pull-off force initially increased during cycling and showed a maximum value of 5.704 kN at ∼100,000 cycles, which is equivalent to gait cycles performed in approximately 36 days. Overall, assembly force, initial component settling, and interface corrosion primarily determine the force required to distract the modular components. One million cycles fatigue failure of the neck can be expected at a maximum compression load of -6.5 kN. No component failure was observed during quasistatic compression; rather the neck deformed plastically and the ultimate compression load-bearing capacity was -13 kN.