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Diamond-like carbon (DLC) coatings doped with bioactive elements of silver (Ag) and copper (Cu) have been receiving increasing attention in the last decade, particularly in the last 5 years, due to their potential to offer a combination of enhanced antimicrobial and mechanical performance. These multi-functional bioactive DLC coatings offer great potential to impart the next generation of load-bearing medical implants with improved wear resistance and strong potency against microbial infections. This review begins with an overview of the status and issues with current total joint implant materials and the state-of-the art in DLC coatings and their application to medical implants. A detailed discussion of recent advances in wear resistant bioactive DLC coatings is then presented with a focus on doping the DLC matrix with controlled quantities of Ag and Cu elements. It is shown that both Ag and Cu doping can impart strong antimicrobial potency against a range of Gram-positive and Gram-negative bacteria, but this is always accompanied so far by a reduction in mechanical performance of the DLC coating matrix. The article concludes with discussion of potential synthesis methods to accurately control bioactive element doping without jeopardising mechanical properties and gives an outlook to the potential long-term impact of developing a superior multifunctional bioactive DLC coating on implant device performance and patient health and wellbeing. Multi-functional diamond-like carbon (DLC) coatings doped with bioactive elements of silver (Ag) and copper (Cu) offer great potential to impart the next generation of load-bearing medical implants with improved wear resistance and strong potency against microbial infections. This article provides a critical review of the state-of-the-art in Ag and Cu doped DLC coatings, beginning with an overview of the current applications of DLC coatings in implant technology followed by a detailed discussion of Ag/Cu doped DLC coatings with particular focus on the relationship between their mechanical and antimicrobial performance. Finally, it ends with a discussion on the potential long-term impact of developing a truly multifunctional ultra-hard wearing bioactive DLC coating to extend the lifetime of total joint implants. [Display omitted] [ABSTRACT FROM AUTHOR]

Total Hip Arthroplasty has been a revolutionary technique in restoring mobility to patients with damaged hip joints. The introduction of modular components of the hip prosthesis allowed for bespoke solutions based on the requirements of the patient. The femoral stem is designed with a conical trunnion to allow for assembly of different femoral head sizes based on surgical requirements. The femoral head diameters for a metal-on-polyethylene hip prosthesis have typically ranged between 22 mm and 36 mm and are typically manufactured using Cobalt–Chromium alloy. A smaller femoral head diameter is associated with lower wear of the polyethylene, however, there is a higher risk of dislocation. In this study, a finite element model of a standard commercial hip arthroplasty prosthesis was modelled with femoral head diameters ranging from 22 mm to 36 mm to investigate the wear evolution and material loss at both contacting surfaces (acetabular cup and femoral stem trunnion). The finite element model, coupled with a validated in-house wear algorithm modelled a human walking for 10 million steps. The results have shown that as the femoral head size increased, the amount of wear on all contacting surfaces increased. As the femoral head diameter increased from 22 mm to 36 mm, the highly cross-linked polyethylene (XLPE) volumetric wear increased by 61% from 98.6 mm3 to 159.5 mm3 while the femoral head taper surface volumetric wear increased by 21% from 4.18 mm3 to 4.95 mm3. This study has provided an insight into the amount of increased wear as the femoral head size increased which can highlight the life span of these prostheses in the human body. [ABSTRACT FROM AUTHOR]

Total hip replacement with metal-on-polymer hip prostheses is the most common treatment for late-stage osteoarthritis. However, the wear debris generated from the polymer acetabular liner remains a problem. Alternative materials with claimed superior wear properties have been proposed to overcome this problem. In this study, the wear behaviour of carbon fibre reinforced polyether ether ketone (CFR PEEK) was investigated under different contact stresses that are observed in the natural hip joint. A 50-station pin-on-disc machine (SuperCTPOD) was used to investigate the wear behaviour of 50 CFR PEEK pins articulated against cobalt chromium (CoCr) discs under five different contact stresses, namely 1.11, 1.38, 1.61, 2.00 and 5.30 MPa. The results showed that the wear rates of the pins did not differ significantly between groups under different contact stresses. In addition, CFR PEEK produced lower wear rates than ultrahigh molecular weight polyethylene and cross-linked polyethylene. However, the weight of the CoCr discs was found to decrease significantly at the end of the wear test, which was indicative of metallic wear. The findings of this study indicated that, despite having relatively low wear rates, CFR PEEK is not a good alternative to be utilised against orthopaedic metals. [ABSTRACT FROM AUTHOR]

Wear of polyethylene is a current limitation in the long-term survival of reverse shoulder arthroplasties (RSAs). The purpose of this study was to investigate, for the first time, the influence of a combination of clinically relevant activities of daily living (ADLs) as patterns of motion and loading on the wear of ultra-high molecular-weight polyethylene (UHMWPE) in RSA. This physiological combined cycle, termed "repeated-motion-load", was applied on four new samples of a commercially available reverse shoulder prosthesis for five million cycles using the unique Newcastle Shoulder Wear Simulator. This resulted in a mean wear rate of 12.0 ± 3.9 mm3/million cycles for the UHMWPE components in combination with metallic glenospheres, while the average articulating UHMWPE surface roughness reduced from 692 ± 132 nm Sa to 42 ± 29 nm Sa. fx1 [ABSTRACT FROM AUTHOR]

Total hip replacement (THR) is one of the most successful orthopaedic surgeries; however, failures can occur due to adverse reactions to wear debris. Recently, a large number of failures linked to the release of metal particles from the taper junction between femoral head and femoral stem have been reported. One possible reason for this may be design variations such as taper mismatches associated with the taper and trunnion angles. Could a large taper mismatch lead to inappropriate contact mechanics and increase relative micromotion and thus wear? In this study, 3D finite element (FE) models of a commercial THR from a perfectly matched interface to large taper mismatches and a wear algorithm were used to investigate the extent of wear that could occur at this junction and identify the optimum tolerances in order to reduce the wear. A co-ordinate measuring machine (CMM) was used to analyse the wear depth and volumetric wear rate of the tapers of 54 explanted 36 mm diameter Cobalt Chromium femoral heads, which had been in service for 5.1 years in average, to validate the FE analyses. It was found that a large taper mismatch (e.g. 9.12´) results in a high wear rate (2.960 mm 3 per million load cycles). Such wear rates can have a major negative effect on the clinical outcomes of these implants. It was also found that even a slight reduction in mismatch significantly reduced the magnitude of the wear rates (0.069 mm 3 per million load cycles on average for 6´ taper mismatch). It is recommended that the cone angles of femoral head and femoral trunnion should be manufactured to produce a taper mismatch of less than 6´ at the taper junction. [ABSTRACT FROM AUTHOR]

As the number of young and active individuals undergoing Total Hip Arthroplasty (THA) are increasing yearly, there is a need for hip prostheses to have increased longevity. Current investigations into the longevity of these prostheses only include walking as the patient's activity as there is limited data on the amount and intensity of other activity performed by the patient. To further understand the evolution of wear and increase the longevity of these implants, the impact of different activities on the hip prosthesis needs to be investigated. In this study, a finite element model and wear algorithm was developed to simulate both walking and bicycling over a 5-year period. The XLPE acetabular cup volumetric wear rate was found to be 33 mm3/yr while the femoral head taper wear rates were between 0.01 – 0.39 mm3/yr. The results showed that by adding bicycling of up to 80 km per week with normal walking activity, the XLPE mean volumetric wear rate increased by 67% and the metallic mean volumetric wear rate by 11%. However, the patient may gain further health benefits from this additional activity. Assistive electric bikes may also be used to further reduce the loads on the hip joint, allowing for lower amounts of wear. [ABSTRACT FROM AUTHOR]

Explant analyses are key to better understanding the effectiveness of medical implants in replacing natural joints. For the first time, an explanted Discocerv cervical disc was examined. The implant utilised the articulation of a caudal zirconia cup (inferior component) and a cephalic alumina head (superior component). The articulating surface of the superior alumina head had an average surface roughness of 0.016 ± 0.003 μm (Sa) and the articulating surface of the inferior zirconia cup had an average surface roughness of 0.015 ± 0.002 μm (Sa). Both articulating surfaces had negative skewness, indicating the removal of local peaks. The difference between the average surface roughness of the components was not significant (p-value: 0.741). Dark grey marks were observed on both of the articulating surfaces, which were found to be adhered titanium debris that was generated due to component impingement. This titanium debris may explain the small amount of metallosis that was reported at explantation. Some transfer of zirconium to the alumina articulating surface was also seen. [ABSTRACT FROM AUTHOR]

Although huge research efforts have been devoted to wear analysis of ultra-high molecular weight polyethylene (UHMWPE) in hip and knee implants, shoulder prostheses have been studied only marginally. Recently, the authors presented a numerical wear model of reverse total shoulder arthroplasties (RTSAs), and its application for estimating the wear coefficient k from experimental data according to different wear laws. In this study, such model and k expressions are exploited to investigate the sensitivity of UHMWPE wear to implant size and dimensional tolerance. A set of 10 different geometries was analysed, considering nominal diameters in the range 36–42 mm, available on the market, and a cup dimensional tolerance of +0.2, −0.0 mm (resulting in a diametrical clearance ranging between 0.04–0.24 mm), estimated from measurements on RTSAs. Since the most reliable wear law and wear coefficient k for UHMWPE are still controversial in the literature, both the Archard law (AR) and the wear law of UHMWPE (PE), as well as four different k expressions were considered, carrying out a total of 40 simulations. Results showed that the wear volume increases with the implant size and decreases with the dimensional tolerance for both the wear laws. Interestingly, different trends were obtained for the maximum wear depth vs. clearance: the best performing implants should have a high conformity according to the AR law but low conformity for the PE law. However, according to both laws, wear is highly affected by both implant size and dimensional tolerance, although it is much more sensitive to the latter, with up to a twofold variation of wear predicted. Indeed, dimensional tolerance directly alters the clearance, and therefore the lubrication and contact pressure distribution in the implant. Rather surprisingly the role of dimensional tolerance has been completely disregarded in the literature, as well as in the standards. Furthermore, this study notes some important issues for future work, such as the validation of wear laws and predictive wear models and the sensitivity of k to implant geometry. [ABSTRACT FROM AUTHOR]

In the present study, numerical and experimental wear investigations on reverse total shoulder arthroplasties (RTSAs) were combined in order to estimate specific wear coefficients, currently not available in the literature. A wear model previously developed by the authors for metal-on-plastic hip implants was adapted to RTSAs and applied in a double direction: firstly, to evaluate specific wear coefficients for RTSAs from experimental results and secondly, to predict wear distribution. In both cases, the Archard wear law (AR) and the wear law of UHMWPE (PE) were considered, assuming four different k functions. The results indicated that both the wear laws predict higher wear coefficients for RTSA with respect to hip implants, particularly the AR law, with k values higher than twofold the hip ones. Such differences can significantly affect predictive wear model results for RTSA, when non-specific wear coefficients are used. Moreover, the wear maps simulated with the two laws are markedly different, although providing the same wear volume. A higher wear depth (+51%) is obtained with the AR law, located at the dome of the cup, while with the PE law the most worn region is close to the edge. Taking advantage of the linear trend of experimental volume losses, the wear coefficients obtained with the AR law should be valid despite having neglected the geometry update in the model. [ABSTRACT FROM AUTHOR]

Abstract: One of the claimed advantages of metal-on-metal total hip replacements is that they ‘self-polish’ in the body, however this assertion has not been supported by quantitative data. Two pairs of components, each consisting of a femoral head and acetabular cup, were obtained at revision surgery. They were subject to topographical analysis using a non-contacting profilometer. In the ‘worn’ regions a reduction in surface roughness was seen alongside a change in skewness values from positive to negative, while elastohydrodynamic theory suggested an improvement towards mild mixed lubrication during gait. Therefore self-polishing of metal-on-metal total hip replacements can occur in vivo. [Copyright &y& Elsevier]

Abstract: Due to their recent introduction there are few studies of retrieved resurfacing hip prostheses. Nine such components associated with groin pain in patients, and five associated with early fracture of the femur, were obtained and analysed using a roundness measuring machine. While the ‘fracture’ components showed no more than 3μm out of roundness, components associated with groin pain showed between 15 and 92μm out of roundness values. These latter results indicate wear and correlated with high metal ion levels in these patients, therefore the groin pain was likely associated with an adverse reaction to excessive metal wear debris. [Copyright &y& Elsevier]

Abstract: Various designs of two-piece finger prosthesis with conforming spherical surfaces have been proposed. These were compared by calculating the lubrication regime for the material combinations and operating conditions expected at the metacarpophalangeal joints of the fingers. Consideration was given to a range of loads from 2 to 50N, a range of entraining velocities from 0 to 30mm/s, and a range of prosthesis radii from 3 to 10mm. This theoretical lubrication analysis indicated that the optimum material combination of those available for two-piece metacarpophalangeal prostheses is in the order: ceramic-on-ceramic; metal-on-metal; pyrocarbon-on-pyrocarbon; and metal-on-polymer. However, it should be recognised that other factors may take precedence when choosing a material combination for a design of finger prosthesis. [Copyright &y& Elsevier]

• Fractography of explanted spinal rods illustrate multiple failure mechanisms. • Evidence of corrosion recognises that the pins have snapped long before explantation. • Failure modes illustrates the complexity of loading in spinal growing rods. The MAGnetic Expansion Control (MAGEC) spinal implant has transformed the treatment of early-onset scoliosis (i.e. abnormal curvature of the spine in children). Despite the innovative solution, the MAGEC device has encountered various performance issues. One component that has been frequently reported amongst the failure issues is the drive pin and the cause of these reoccurring fractures may be associated with multiple factors including over-loading, fatigue, and corrosion. This study aimed to examine the failure of eight broken drive pins from explanted MAGEC rods through fractography analysis, to better understand the factors leading to their fracture. The fracture surface of the drive pins was examined using Scanning Electron Microscopy (SEM). The clinical data were compared against observed failure modes. The fracture surfaces of four drive pins showed low cycle (high stress) or high cycle (low stress) fatigue failure mechanisms. The other four drive pins displayed environment assisted stress corrosion cracking. Almost all samples had evidence of corrosion after fracture with the amount of corrosion implying fracture occurred a relatively long time before explantation. Since multiple failure mechanisms of low cycle fatigue, high cycle fatigue or simultaneous effect of tension and corrosive environment have been observed, the fracture mechanisms illustrate the complexity of loading in these spinal growing rods. Evidence of corrosion after the failure recognises that the pins have snapped long before the device was explanted. [ABSTRACT FROM AUTHOR]

Using a 50-station pin-on-disc (SuperCTPOD) machine, the influence of lubricant viscosity on the wear of vitamin E blended crosslinked polyethylene was investigated. Five different test lubricants were prepared by mixing different concentrations of carboxymethyl cellulose powder with deionised water. The viscosity range of the lubricants was 0.002–0.155 Pa, a range that represents the viscosities of diseased and healthy synovial fluids. Five groups of pins (10 pins in each group) were articulated against cobalt chromium discs. Wear was measured in terms of weight loss from each pin and disc for every group. Every 500,000 cycles the experiment was stopped to take gravimetric measurements along with roughness measurements of the articulating surfaces. The test discs did not show a significant change in weight after 2.5 million cycles of testing (p > 0.05). For the pins, the group tested with the lowest viscosity (0.002 Pa) produced the highest wear rate, namely 0.931 mg/million cycles, and the wear rates of the other groups were 0.074, 0.027, 0.034 and 0.021 mg/million cycles respectively. The wear rates calculated for the five groups were all lower than the wear rates recorded for ultrahigh molecular weight polyethylene and not significantly different to crosslinked polyethylene. In addition, apart from group 1 pins (tested with the lowest lubricant viscosity (0.002 Pa)), the machining marks on the other pins were still present after 2.5 million cycles of testing, indicating low wear. [ABSTRACT FROM AUTHOR]

Explant analysis can provide key insights to understanding failures of artificial joints and thus how they might be improved for the ultimate benefit of patients. There are no previous reports of explant analysis of an artificial wrist joint. In this study, an explanted metal-on-polymer Maestro wrist was analysed both in macro and nanoscales to estimate its biotribological performance. The articulation was formed between a cobalt chromium carpal head and an ultrahigh molecular weight polyethylene bearing. The surface roughness values of its articulating surfaces and the backside of the articulation were measured. On average, the articulating surface roughness values were calculated as 0.06 ± 0.02 μm and 1.29 ± 0.63 μm for the cobalt chromium carpal head and ultrahigh molecular weight polyethylene bearing, respectively. Both surfaces had negative skewness, indicating a preponderance of valleys. On the articulating surface of the carpal head, light scratches were observed, and no impingement was observed throughout the component. The polymeric surface had a polished appearance. It had unidirectional scratches at the centre of the articulation, pits of different sizes on its articulating surface, and matt white subsurface regions. The backside of the UHMWPE bearing and the convex surface of the radial body that it was sitting on, were found to have average surface roughness values of 4.23 ± 0.69 μm and 5.57 ± 1.05 μm, respectively. The difference in the means was not significant (p > 0.05). Taking the articulating surface roughness values, the lubrication regime that the explanted Maestro wrist operated under in vivo was estimated for varying physiological conditions, i.e. varying loads, entraining velocities and lubricant viscosities. In every case considered, the explant was found to operate under boundary lubrication. [ABSTRACT FROM AUTHOR]

The generation of polyethylene wear debris, and the subsequent tissue reaction to such debris is considered to be a limitation in the long-term survival of shoulder arthroplasties. The purpose of this study was to investigate, for the first time, the wear of a novel PyroCarbon-on-Polyethylene (PyCoP) shoulder arthroplasty system. A 5 million cycle wear test was performed on PyroCarbon humeral heads, which were articulated against commercially available polyethylene glenoid insert components to form an anatomic total shoulder arthroplasty (aTSA). A "Repeat-motion-load" physiological combined cycle was applied using the unique Newcastle Shoulder Wear Simulator. Wear was assessed gravimetrically, and the change of the surface roughness was measured with a non-contacting profilometer. The mean wear rate of the ultra-high molecular weight polyethylene (UHMWPE) components was 19.3 ± 9.5 mm3/million cycles after 5 million cycles of testing. The roughness value, S a , of the UHMWPE glenoid inserts, reduced, changing from 296 ± 28 nm S a to 32 ± 8 nm S a. In contrast, the mean roughness of the PyroCarbon humeral heads remained in the same range (21 ± 2 nm S a to 20 ± 10 nm S a). There was no reduction in weight (no measurable wear) of the PyroCarbon humeral heads over the duration of testing. This study is the first to describe the wear performance of UHMWPE glenoid inserts against PyroCarbon humeral heads. No significant difference in the wear of UHMWPE was found in comparison with published studies. • This study investigated for the first time the wear performance of UHMWPE glenoid inserts against PyroCarbon humeral heads. • Polyethylene wear rate against PyroCarbon counterparts was similar to previous in vitro studies on metal-on-polyethylene. • PyroCarbon components did not exhibit a loss in weight or an appreciable change in surface roughness over the test duration. [ABSTRACT FROM AUTHOR]

The generation of particulate debris at the taper junction of total hip replacements (THRs), can cause failure of the artificial hip. The taper surfaces of femoral heads and trunnions of femoral stems are generally machined to a certain roughness to enhance fixation. However, the effect of the surface roughness of these surfaces on the fixation, wear and consequently clinical outcomes of the design is largely unknown. In this study, we asked whether a micro-grooved trunnion surface finish (1) improves the fixation and (2) reduces the wear rate at the taper junction of THRs. We used 3D finite element (FE) models of THRs to, firstly, investigate the effect of initial fixation of a Cobalt-Chromium femoral head with a smooth taper surface mated with a Titanium (1) micro-grooved and (2) smooth, trunnion surface finishes. Secondly, we used a computational FE wear model to compare the wear evolution between the models, which was then validated against wear measurements of the taper surface of explanted femoral heads. The fixation at the taper junction was found to be better for the smooth couplings. Over a 7 million load cycle analysis in - silico , the linear wear depth and the total material loss was around 3.2 and 1.4 times higher for the femoral heads mated with micro-grooved trunnions. It was therefore concluded that smooth taper and trunnion surfaces will provide better fixation at the taper junction and reduce the volumetric wear rates. [ABSTRACT FROM AUTHOR]

• This is the first reported explant analysis of a Mobi-C cervical disc. • It was shown that migration of the insert occurred, leading to compression of the spinal cord, pain and eventually a revision operation. • While they may provide more normal biomechanics, non-constrained designs, such as the Mobi-C, may also be associated with excessive migration of the insert in vivo. • In common with explanted metal-on-polymer joint replacements, the metal articulating surfaces of the disc became rougher while the polyethylene insert became smoother in vivo. Ex vivo analysis of artificial discs is essential to better understand their ability to replace degenerated intervertebral discs. The Mobi-C differs from some other contemporary disc designs in that it has a mobile polyethylene insert that is sandwiched between superior and inferior cobalt chromium endplates. While some studies claim the Mobi-C to have restored normal cervical spinal biomechanics, others have noted high levels of migration. Our objective was to contribute to this debate by, for the first time, analysing an explanted Mobi-C cervical disc which was removed due to worsening myelopathy at the nano and macro scales. Intraoperatively, the insert was found to have excessively migrated and it compressed the spinal cord. Roughness was measured as 0.016 ± 0.006 μm (Sa) and 0.055 ± 0.020 μm (Sa) for the superior and inferior plates, and 1.210 ± 0.154 μm (Sa) and 0.446 ± 0.083 μm (Sa) for the superior and inferior surfaces of the insert. Compared to unworn surfaces, the roughness increased for the superior and inferior plates and decreased for both surfaces of the insert. However, the only statistically significant change occurred on the articulating surface of the inferior plate (p = 0.04). At the nanoscale, valleys dominated the articulating surfaces. The superior plate had a burnished appearance whereas the inferior plate appeared matt. Impingement was observed on the endplates. The insert was severely damaged, burnished and had scratches. Additionally, subsurface whitening and internal cracking were observed on the insert. [ABSTRACT FROM AUTHOR]

It has been proposed that an increased surface roughness of the femoral components of Total Knee Replacements (TKRs) may be a contributing factor to the accelerated wear of the polyethylene (PE) bearing and ultimately prosthesis failure. Oxidised Zirconium was introduced to the orthopaedic market in an attempt to reduce PE wear associated failures and increase the longevity of the prosthesis. In this study, non-contacting profilometry was used to measure the surface roughness of the femoral components of 6 retrieved TKRs (3 Oxidised Zirconium (OxZr) and 3 Cobalt Chromium alloy (CoCr) femoral components) and 2 as-manufactured femoral components (1 OxZr and 1 CoCr). A semi-quantitative method was used to analyse the damage on the retrieved PE components. The S a values for the retrieved OxZr femoral components ( S a = 0.093 µm ± 0.014) and for the retrieved CoCr femoral components ( S a = 0.065 µm ± 0.005) were significantly greater ( p < .05) than the roughness values for the as-manufactured femoral components (OxZr S a = 0.061 µm ± 0.004 and CoCr S a = 0.042 µm ± 0.003). No significant difference was seen between the surface roughness parameters of the retrieved OxZr and retrieved CoCr femoral components. There was no difference between the PE component damage scores for the retrieved OxZr TKRs compared to the retrieved CoCr TKRs. These results agree with other studies that both OxZr and CoCr femoral components roughen during time in vivo but the lack of difference between the surface roughness measurements of the two materials is in contrast to previous topographical reports. Further analysis of retrieved OxZr TKRs is recommended so that a fuller appreciation of their benefits and limitations be obtained. [ABSTRACT FROM AUTHOR]