Tribo-corrosion properties of cobalt-based medical implant alloys in simulated biological environments

Tribological problems and corrosion degradation have been recognized as essential risks for total joint replacements, especially for all-metal arthroplasty. Few studies have focused on the interactions between tribology and corrosion (tribocorrosion) for implant materials. This paper addresses the importance of understanding tribocorrosion and the evaluation of such materials in simulated biological environments. Due to the complex effect of proteins on tribocorrosion, which has been demonstrated in previous studies, this study focuses towards understanding the effects of amino acids as aspects of material degradation. Dulbecco’s Modified Eagle’s Medium (DMEM) is a cell culture solution. It contains comparable amount and types of amino acids to normal synovial fluid in human joints. 0.36% NaCl solution was employed to isolate the biological species. Three materials were tested; High carbon (HC) CoCrMo (contains 0.19% carbon), low carbon (LC) CoCrMo (widely used materials for total joint replacement) and stainless steel UNS S31603 (316L). Integrated electrochemical tests supported by measurement of friction and near surface chemical analysis were carried out to enable their tribocorrosion behaviour to be fully characterized. As a general conclusion, amino acids were found to react with materials under tribological contacts and form complex organometallic/oxides which lubricate the metallic sample surface. Tribocorrosion plays a very important role in material degradation in the studied environments. HC CoCrMo shows superior wear, corrosion and tribocorrosion resistance – the material characteristics and their effect on the different tribocorrosion processes are discussed

Development of a Co-Cr-Mo to Tantalum Transition using LENS for Orthopedic Applications

Biomedical implant material research using additive manufacturing is a popular field of study. Many potential material combinations exist which, if implemented properly, could have a significantly positive effect on implant life and functionality. One material combination of interest is attaching porous Ta bone ingrowth material to a CoCrMo corrosion and wear resistant bearing surface. An investigation of the ability of the LENS process to join Ta to CoCrMo was undertaken. Direct joining of CoCrMo to Ta was known to be problematic, and thus transitional layers of other biomedically-compatible materials were investigated. It was determined that a transitional layer of zirconium appeared to be the best transitional material for this application due to its excellent biocompatibility, followed by stainless steel, with a lesser biocompatibility but better adhesive properties.Mechanical Engineerin

In silico evaluation of the thermal stress induced by MRI switched gradient fields in patients with metallic hip implant

This work focuses on the in silico evaluation of the energy deposed by MRI switched gradient fields in bulk metallic implants and the consequent temperature increase in the surrounding tissues. An original computational strategy, based on the subdivision of the gradient coil switching sequences into sub-signals and on the time-harmonic electromagnetic field solution, allows to realistically simulate the evolution of the phenomena produced by the gradient coils fed according to any MRI sequence. Then, Pennes' bioheat equation is solved through a Douglas-Gunn time split scheme to compute the time-dependent temperature increase. The procedure is validated by comparison with laboratory results, using a component of a realistic hip implant embedded within a phantom, obtaining an agreement on the temperature increase better than 5%, lower than the overall measurement uncertainty. The heating generated inside the body of a patient with a unilateral hip implant when undergoing an Echo-Planar Imaging (EPI) MRI sequence is evaluated and the role of the parameters affecting the thermal results (body position, coil performing the frequency encoding, effects of thermoregulation) is discussed. The results show that the gradient coils can generate local increases of temperature up to some kelvin when acting without radiofrequency excitation. Hence, their contribution in general should not be disregarded when evaluating patients' safety

Effects of material properties of femoral hip components on bone remodeling

Bone loss around femoral hip stems is one of the problems threatening the long-term fixation of uncemented stems. Many believe that this phenomenon is caused by reduced stresses in the bone (stress shielding). In the present study the mechanical consequences of different femoral stem materials were investigated using adaptive bone remodeling theory in combination with the finite element method. Bone-remodeling in the femur around the implant and interface stresses between bone and implant were investigated for fully bonded femoral stems. Cemented stems (cobalt-chrome or titanium alloy) caused less bone resorption and lower interface stresses than uncemented stems made from the same materials. The range of the bone resorption predicted in the simulation models was from 23% in the proximal medial cortex surrounding the cemented titanium alloy stem to 76% in the proximal medial cortex around the uncemented cobalt-chrome stem. Very little bone resorption was predicted around a flexible, uncemented iso-elastic stem, but the proximal interface stresses increased drastically relative to the stiffer uncemented stems composed of cobalt-chrome or titanium alloy. However, the proximal interface stress peak was reduced and shifted during the adaptive remodeling process. The latter was found particularly in the stiffer uncemented cobalt-chrome-molybdenum implant and less for the flexible isoelastic implant

DMLS and Manufacturing

Direct Metal Laser Sintering (DMLS) has been used for manufacturing prototypes, functional metal components and prototype tools for more than 10 years. During this period the technology has advanced to a level where direct production of complex metallic parts for various applications is everyday life and manufacturing with its various challenges is its main target. The shift from prototyping to production requires changes in the technology and also in the organizations taking part in the shift. This paper presents the latest status of the DMLS technology and materials development trends for different application areas using EOSINT M270 laser sintering machine. Commercially launched materials include presently biomedical materials like Titanium and Cobalt Chrome alloys, ultra high strength Maraging Steel alloy, Stainless Steels and other high-end engineering materials. In addition, there are many materials which have been developed for evaluation purposes, waiting for industrial applications.Mechanical Engineerin

Inlet protein aggregation: a new mechanism for lubricating film formation with model synovial fluids.

This paper reports a fundamental study of lubricant film formation with model synovial fluid components (proteins) and bovine serum (BS). The objective was to investigate the role of proteins in the lubrication process. Film thickness was measured by optical interferometry in a ball-on-disc device (mean speed range of 2-60 mm/s). A commercial cobalt-chromium (CoCrMo) metal femoral head was used as the stationary component. The results for BS showed complex time-dependent behaviour, which was not representative of a simple fluid. After a few minutes sliding BS formed a thin adherent film of 10-20 nm, which was attributed to protein absorbance at the surface. This layer was augmented by a hydrodynamic film, which often increased at slow speeds. At the end of the test deposited surface layers of 20-50 nm were measured. Imaging of the contact showed that at slow speeds an apparent 'phase boundary' formed in the inlet just in front of the Hertzian zone. This was associated with the formation of a reservoir of high-viscosity material that periodically moved through the contact forming a much thicker film. The study shows that proteins play an important role in the film-forming process and current lubrication models do not capture these mechanisms

Fretting Corrosion Behavior of Additive Manufactured and Cryogenic-Machined Ti6Al4V for Biomedical Applications

Metal ion release, caused by synergistic effect of wear and corrosion, is one of the major concerns related to the prostheses lifetime. In this work, samples of additive manufactured Ti6Al4V are machined under dry cutting and cryogenic cooling conditions and their performances in terms of corrosion and fretting corrosion response are investigated. A wet and temperature-controlled apparatus equipped with an electro-chemical cell is designed and set-up in order to evaluate the fretting corrosion effect acting at the interfaces. The obtained results show that the cryogenic machining improves the corrosion and fretting corrosion behavior of the investigated additive manufactured Ti6Al4V

Tribocorrosion behaviour of hot pressed CoCrMo−Al2O3 composites for biomedical applications

Alumina/alumina wear couple can lower the wear rates and thus metallic ion releasing on load bearing metallic implant materials. However, the low fracture toughness of ceramics is still a major concern. Therefore, the present study aims to process and to triboelectrochemically characterise the 5 and 10 vol.-%Al2O3 reinforced CoCrMo matrix composites. Corrosion and tribocorrosion behaviour of the composites were investigated in 8 g L21 NaCl solution at body temperature. Corroded and worn surfaces were investigated by a field emission gun scanning electron microscope equipped with energy dispersive X-ray spectroscopy. After tribocorrosion experi- ments, wear rates were calculated using a profilometer. Results suggest that Al2O3 particle addition decreased the tendency of CoCrMo alloy to corrosion under both static and tribocorrosion conditions. However, no significant influence on the corrosion and wear rates was observed in composites mainly due to increased porosity and insufficient matrix/ reinforcement bonding.This study was supported by the Portuguese Foundation for Science and Technology (FCT-Portugal), under project no. EXCL/EMS-TEC/0460/2012, and The Calouste Gulbenkian Foundation through 'Programa de Mobilidade Academica para Professores'. The authors also would like to thank Professor A. Ramalho (Universidade de Coimbra) for the provision of profilometry facilities

Finite element analysis of TMJ implant under clenching loads

The temporomandibular joint is one of the most complex anatomical structures and is exposed to high stress conditions during daily movements. Replacing the joint is normally done only in severe cases as success rate of the replaced joint is not as encouraging as other joint replacements. The design of TMJ implant which includes material selection plays a significant role in its success. Two different biomaterials—Ti–6Al–4V and CoCrMo— under static loads simulating five clenching tasks were analysed in this study. A three dimensional model of an adult mandible was developed from Computed Tomography image dataset, as well as a generic TMJ implant with fixation. All the applied clenching tasks consisted of nine principle muscles. The results showed that both materials were totally safe under these loading conditions. However Ti–6Al–4V showed a comparatively lower stress level