Mechanical and numerical characterization of ceramic femoral components for hip resurfacing arthroplasty.

Hip resurfacing arthroplasty may have distinct advantages for young and active patients, but large metal-on-metal bearings can be associated with increased wear, adverse tissue reactions and higher rate of implant loosening. Ceramic wear couples are a commonly used alternative to metals and therefore might be an alternative for hip resurfacing arthroplastys. The aim of this study was to evaluate the mechanical strength of femoral components made of an alumina-toughened zirconia composite by means of experimental testing and finite element analysis. For the mechanical characterization, ceramic femoral components (Ø: 48 mm) were tested under compression loading experimentally until fracture occurred or a maximum load of 85 kN was obtained. The femoral components were either loaded against a ceramic cup or a copper ring (outer diameter Ø: 7.0 mm). In addition, the complex geometry of the ceramic femoral component was simplified, and only the stem was loaded in a cantilever test until fracture. In addition, the fracture tests were numerically simulated to investigate the influence of additional loading conditions and geometric parameters, which were not experimentally tested. The experimental data were used for validation of the finite element analysis. None of the tested ceramic femoral components fractured at a compression load of 85 kN when they were loaded against a ceramic cup at an inclination angle of 45°. When the femoral components were loaded against a copper ring, the femoral components fractured at 29.9 kN at a testing angle of 45°. The fracture load was reduced when an angle of 30° and increased when an angle of 60° was simulated. Using an experimental cantilever test, the stem of the femoral component fractured at 1124.0 N. When the stem length was increased or the diameter was reduced by 10% in the finite element analysis, the fracture load was reduced. Decreasing the length or increasing the diameter led to an increase of the fracture load. The strongest influence was found for the reduction of the transition radius of the stem, with a decrease of the fracture load up to 27.2%. The analyzed femoral components made of alumina-toughened zirconia (ATZ) showed sufficient mechanical capability to withstand high loadings during unfavorable loading conditions. However, further biomechanical and tribological investigations are required before clinical application.

Combined wear and ageing of ceramic-on-ceramic bearings in total hip replacement under edge loading conditions.

Ceramic-on-ceramic bearings in total hip replacement have shown the potential to provide low wear solutions in hip replacement. Assessing the tribological performance of these materials is important to predict their long-term performance in patients. In this study, a methodology was devised to assess the tribological in vitro behaviour of composite ceramics under combined adverse edge loading conditions and accelerated ageing. Two commercial ceramic composites were considered, namely Alumina-Toughened Zirconia (ATZ, ceramys®) and Zirconia-Toughened Alumina (ZTA, symarec®). The bearing couples were studied using the Leeds Mark II hip joint simulator for a total of eight million cycles, the first two million under normal gait (no edge loading) and the following six million cycles with the addition of edge loading conditions driven by medial-lateral separation. The bearing couples underwent hydrothermal ageing using an accelerated protocol in autoclave every million cycles. The influence of edge loading combined with ageing was significant for ATZ bearings, resulting in a slower overall ageing kinetics over the wear stripe than on the control heads. During the autoclave ageing steps, the monoclinic fraction increased more over the wear stripe area than over the unworn area. Both results thus indicated that the monoclinic phase was removed during shocks induced by edge loading. The wear performance of the two materials were similar exhibiting relatively low wear rates and low level of microstructural damage for these clinically relevant adverse conditions.

Wear of composite ceramics in mixed-material combinations in total hip replacement under adverse edge loading conditions.

Ceramic composites have performed very well under adverse edge loading conditions when used in like-on-like configurations, where the femoral head and acetabular cup are of the same material. The aim of this study was to determine the wear of pure alumina (Al2 O3 ), alumina toughened zirconia (ATZ) and zirconia toughened alumina (ZTA) when used in mixed bearing combinations, under edge loading conditions due to translational mal-positioning. The head-on-cup configurations of three ceramic materials were ATZ-on-ZTA, ZTA-on-ATZ, Al2 O3 -on-ATZ, ATZ-on-Al2 O3 , Al2 O3 -on-ZTA, and ZTA-on-Al2 O3 . They were tested on the Leeds II hip simulator under microseparation conditions. The bedding in and steady state wear rates of ATZ-on-ZTA were 1.16mm3 /million cycles and 0.18mm3 /million, respectively, and for ATZ-on-Al2 O3 were 0.66 mm3 /million cycles and 0.20 mm3 /million, respectively. The wear rates of the other bearing combinations under these adverse microseparation conditions, Al2 O3 -on-ATZ, Al2 O3 -on-ZTA, ZTA-on-ATZ and ZTA-on-Al2 O3 were very low with no clear bedding in and steady state phases, and with steady state wear rates lower than 0.11 mm3 /million. The mixed material combinations tested in this study have shown slightly higher wear rates when compared to ATZ in like-on-like configuration reported previously, but superior wear resistance when compared to alumina-on-alumina bearings tested previously under the same adverse microseparation conditions. © 2016 The Authors Journal of Biomedical Materials Research Part B: Applied Biomaterials Published by Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 105B: 1361-1368, 2017.

Edge loading does not increase wear rates of ceramic-on-ceramic and metal-on-polyethylene articulations.

The mal-positioning of total hip arthroplasty components can result in edge loading conditions. Purpose of this study was to determine if the wear rate of ceramic-on-ceramic and metal-on-polyethylene increases under edge loading conditions. The literature was reviewed to determine which of the commonly used hip bearings is the most forgiving to implant mal-orientation. Two 28-mm ceramic-on-ceramic articulations were tested in vitro: pure alumina (PAL) ceramic versus the new alumina-toughened zirconia (ATZ). Two 28-mm metal-on-polyethylene articulations were tested in vitro: conventional ultrahigh molecular weight polyethylene (UHMWPE) versus highly crosslinked polyethylene (HXLPE) stabilized with vitamin E. All bearings were tested at standard and at highest possible inclination angles. Hip simulator tests were run for five million cycles based on N = 3 tests per condition. The average wear rate of ATZ-on-ATZ is 0.024 mm(3) /Mcycles at 45° and 0.018 mm(3) /Mcycles at 65°. Wear rate of PAL-on-PAL is between 0.02 and 0.03 mm(3) /Mcycles at 45°, as well as 65°. The wear rate of UHMWPE was 31 ± 1 mm(3) /Mcycles at an inclination angle of 45° and 26 ± 1 mm(3) /Mcycles at 80°. The wear rate of vitamin E stabilized HXLPE was 5.9 ± 0.2 mm(3) /Mcycles at 45° and 5.8 ± 0.2 mm(3) /Mcycles at 80°. Edge loading does not increase the wear rate of ceramic-on-ceramic and metal-on-polyethylene articulations. The newest biomaterials showed markedly lower wear rates compared with their conventional counterparts. ATZ-on-ATZ showed the lowest wear rate of all tested pairings, but the vitamin E stabilized HXLPE seems to be the most forgiving material when it comes to implant mal-orientation.

Wear of novel ceramic-on-ceramic bearings under adverse and clinically relevant hip simulator conditions.

Further development of ceramic materials for total hip replacement aim to increase fracture toughness and further reduce the incidence of bearing fracture. Edge loading due to translational mal positioning (microseparation) has replicated stripe wear, wear rates, and bimodal wear debris observed on retrievals. This method has replicated the fracture of early zirconia ceramic-on-ceramic bearings. This has shown the necessity of introducing microseparation conditions to the gait cycle when assessing the tribological performance of new hip replacement bearings. Two novel ceramic matrix composite materials, zirconia-toughened alumina (ZTA) and alumina-toughened zirconia (ATZ), were developed by Mathys Orthopädie GmbH. In this study, ATZ-on-ATZ and ZTA-on-ZTA bearing combinations were tested and compared with alumina-on-alumina (Al2O3-on-Al2O3) bearings under adverse microseparation and edge loading conditions using the Leeds II physiological anatomical hip joint simulator. The wear rate (±95% confidence limit) of ZTA-on-ZTA was 0.14 ± 0.10 mm(3)/million cycles and that of ATZ-on-ATZ was 0.06 ± 0.004 mm(3)/million cycles compared with a wear rate of 0.74 ± 1.73 mm(3)/million cycles for Al2O3-on-Al2O3 bearings. Stripe wear was evident on all bearing combinations; however, the stripe formed on the ATZ and ZTA femoral heads was thinner and shallower that that formed on the Al2O3 heads. Posttest phase composition measurements for both ATZ and ZTA materials showed no significant change in the monoclinic zirconia content. ATZ-on-ATZ and ZTA-on-ZTA showed superior wear resistance properties when compared with Al2O3-on-Al2O3 under adverse edge loading conditions.

Influence of various types of damage on the fracture strength of ceramic femoral heads.

Ceramic-on-ceramic articulations are a frequently used bearing for total hip replacements. This success mainly is due to their excellent tribological properties. Ceramics can withstand high pressure loads due to its brittleness but only low bending stresses. A ceramic ball head fracture is the result of subcritical crack growth. This kind of fracture in vivo can abet by damage or contamination of the stem cone. The main goal of this work is to provide a risk assessment of different possible damage mechanisms and contaminations that may result in lower fracture strength of a ceramic ball head. To simulate potential causes, different types and dimensions of metal wire, foils, hair, and lubricants were inserted between the ceramic ball head and the metal cone of the stem. The test results clearly show that fracture strength is negatively influenced by most of the inhomogeneities between the cone and the head because they increase the peak stresses acting on a part of the ceramic ball head. The results of this article clearly confirm the demand for an undamaged taper fit "free of contamination" between the ceramic head and the metal cone during implantation.

Subcritical crack growth behavior of dispersion oxide ceramics.

Zirconia (Y-TZP) is used as material for components of implants and prostheses because of its high short-term strength. The mechanical long-term reliability, however, is limited for Y-TZP because of hydrothermal aging effects and a pronounced tendency for subcritical crack growth. The hypothesis of this study was that a substantial amount of alumina in a zirconia matrix can help to significantly suppress subcritical crack growth and thereby improve the mechanical long-term reliability. The Weibull parameters as well as the parameters of the subcritical crack growth were determined for Alumina, Y-TZP, and two dispersion ceramics, that is Alumina Toughened Zirconia (ATZ, 20% alumina/80% Y-TZP), and Zirconia Toughened Alumina (ZTA, 75% alumina/25% Y-TZP). The long-term failure probability as a function of service time was predicted for the four ceramics. The parameter n of the subcritical crack growth was approx. 80% higher for ATZ compared to Y-TZP. In consequence, the estimated lifetime revealed a significant better mechanical long-term reliability for ATZ. It can be concluded that tailored dispersion oxide ceramics can address the aging problem of monolithic zirconia. This makes ATZ very interesting for components of joint replacement as well as for dental prostheses and implants.