Early Tibial Component Fractures in a Cementless, 3D-Printed, Titanium Implant

Lam, Alan D.; Duffy, Gavan P.

doi:10.1016/j.artd.2022.08.002

Cited by 7 publications

(8 citation statements)

References 23 publications

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“…When these devices do fracture, it is often associated with electrocautery damage, device design, or processing defects rather than the alloy itself. [58][59][60] However, severe corrosion of titanium is documented at modular taper junctions where fretting occurs and within titanium-titanium modular body interfaces. As hundreds of AM titanium alloy devices gain FDA clearance through the 510 k pathway, including those that articulate in modular junctions like acetabular cups, corrosion remains a concern.…”

Section: Discussionmentioning

confidence: 99%

“…As biomaterials, titanium and its alloys work in that they reproduce the desired function of the tissue and act as load bearers in the hip and knee. When these devices do fracture, it is often associated with electrocautery damage, device design, or processing defects rather than the alloy itself 58–60 . However, severe corrosion of titanium is documented at modular taper junctions where fretting occurs and within titanium‐titanium modular body interfaces.…”

Section: Discussionmentioning

confidence: 99%

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Oxide degradation precedes additively manufactured Ti‐6Al‐4V selective dissolution: An unsupervised machine learning correlation of impedance and dissolution compared to Ti‐29Nb‐21Zr

Kurtz,

Alaniz,

Kurtz

et al. 2023

J Biomedical Materials Res

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Additively manufactured (AM) Ti‐6Al‐4V devices are implanted with increasing frequency. While registry data report short‐term success, a gap persists in our understanding of long‐term AM Ti‐6Al‐4V corrosion behavior. Retrieval studies document β phase selective dissolution on conventionally manufactured Ti‐6Al‐4V devices. Researchers reproduce this damage in vitro by combining negative potentials (cathodic activation) and inflammatory simulating solutions (H2O2‐phosphate buffered saline). In this study, we investigate the effects of these adverse electrochemical conditions on AM Ti‐6Al‐4V impedance and selective dissolution. We hypothesize that cathodic activation and H2O2 solution will degrade the oxide, promoting corrosion. First, we characterized AM Ti‐6Al‐4V samples before and after a 48 h −0.4 V hold in 0.1 M H2O2/phosphate buffered saline. Next, we acquired nearfield electrochemical impedance spectroscopy (EIS) data. Finally, we captured micrographs and EIS during dissolution. Throughout, we used AM Ti‐29Nb‐21Zr as a comparison. After 48 h, AM Ti‐6Al‐4V selectively dissolved. Ti‐29Nb‐21Zr visually corroded less. Structural changes at the AM Ti‐6Al‐4V oxide interface manifested as property changes to the impedance. After dissolution, the log‐adjusted constant phase element (CPE) parameter, Q, significantly increased from −4.75 to −3.84 (Scm−2(s)α) (p = .000). The CPE exponent, α, significantly decreased from .90 to .84 (p = .000). Next, we documented a systematic decrease in oxide polarization resistance before pit nucleation and growth. Last, using k‐means clustering, we established a structure–property relationship between impedance and the surface's dissolution state. These results suggest that AM Ti‐6Al‐4V may be susceptible to in vivo crevice corrosion within modular taper junctions.

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Section: Discussionmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

Oxide degradation precedes additively manufactured Ti‐6Al‐4V selective dissolution: An unsupervised machine learning correlation of impedance and dissolution compared to Ti‐29Nb‐21Zr

Kurtz,

Alaniz,

Kurtz

et al. 2023

J Biomedical Materials Res

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“…Additionally, while corrosion and wear are associated with device failure, patients may rely on a corroding device for years without experiencing clinical symptoms. In contrast, fatigue failure is catastrophic, ending in device fracture a clear breakdown of the device's purpose [62]. Thus, crack prevention is prioritized and is a design consideration.…”

Section: Discussionmentioning

confidence: 99%

Fretting and Fretting Corrosion Behavior of Additively Manufactured Ti-6Al-4V and Ti-Nb-Zr Alloys in Air and Physiological Solutions

Mace,

Kurtz,

Gilbert

2024

JFB

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Additive manufacturing (AM) of orthopedic implants has increased in recent years, providing benefits to surgeons, patients, and implant companies. Both traditional and new titanium alloys are under consideration for AM-manufactured implants. However, concerns remain about their wear and corrosion (tribocorrosion) performance. In this study, the effects of fretting corrosion were investigated on AM Ti-29Nb-21Zr (pre-alloyed and admixed) and AM Ti-6Al-4V with 1% nano yttria-stabilized zirconia (nYSZ). Low cycle (100 cycles, 3 Hz, 100 mN) fretting and fretting corrosion (potentiostatic, 0 V vs. Ag/AgCl) methods were used to compare these AM alloys to traditionally manufactured AM Ti-6Al-4V. Alloy and admixture surfaces were subjected to (1) fretting in the air (i.e., small-scale reciprocal sliding) and (2) fretting corrosion in phosphate-buffered saline (PBS) using a single diamond asperity (17 µm radius). Wear track depth measurements, fretting currents and scanning electron microscopy/energy dispersive spectroscopy (SEM/EDS) analysis of oxide debris revealed that pre-alloyed AM Ti-29Nb-21Zr generally had greater wear depths after 100 cycles (4.67 +/− 0.55 µm dry and 5.78 +/− 0.83 µm in solution) and higher fretting currents (0.58 +/− 0.07 µA). A correlation (R2 = 0.67) was found between wear depth and the average fretting currents with different alloys located in different regions of the relationship. No statistically significant differences were observed in wear depth between in-air and in-PBS tests. However, significantly higher amounts of oxygen (measured by oxygen weight % by EDS analysis of the debris) were embedded within the wear track for tests performed in PBS compared to air for all samples except the ad-mixed Ti-29Nb-21Zr (p = 0.21). For traditional and AM Ti-6Al-4V, the wear track depths (dry fretting: 2.90 +/− 0.32 µm vs. 2.51 +/− 0.51 μm, respectively; fretting corrosion: 2.09 +/− 0.59 μm vs. 1.16 +/− 0.79 μm, respectively) and fretting current measurements (0.37 +/− 0.05 μA vs. 0.34 +/− 0.05 μA, respectively) showed no significant differences. The dominant wear deformation process was plastic deformation followed by cyclic extrusion of plate-like wear debris at the end of the stroke, resulting in ribbon-like extruded material for all alloys. While previous work documented improved corrosion resistance of Ti-29Nb-21Zr in simulated inflammatory solutions over Ti-6Al-4V, this work does not show similar improvements in the relative fretting corrosion resistance of these alloys compared to Ti-6Al-4V.

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“…Biomaterials currently used for 3D printing in the medical and orthopaedic fields 18,19 include polymers, materials widely used in additive manufacturing because of their ease of structural change due to relatively low melting points; 20,21 metals and alloys, including titanium alloy, a compact, lightweight and highly corrosive-resistant material with osteointegrative properties that make it perfect for replacing missing parts or for support during alignment and surgical cutting. 22,23 FDM is a manufacturing technology adapted for the fabrication of porous bone tissue at low cost, providing good mechanical properties. [24][25][26] In fact, the 3D printing parameters are set by slicing software, which layers the imported 3D model.…”

Section: Introductionmentioning

confidence: 99%

3D-printing of porous structures for reproduction of a femoral bone

et al. 2023

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Background: 3D-printing has shown potential in several medical advances because of its ability to create patient-specific surgical models and instruments. In fact, this technology makes it possible to acquire and study physical models that accurately reproduce patient-specific anatomy. The challenge is to apply 3D-printing to reproduce the porous structure of a bone tissue, consisting of compact bone, spongy bone and bone marrow. Methods: An interesting approach is presented here for reproducing the structure of a bone tissue of a femur by 3D-printing porous structure. Through the process of CT segmentation, the distribution of bone density was analysed. In 3D-printing, the bone density was compared with the density of infill. Results: The zone of compact bone, the zone of spongy bone and the zone of bone marrow can be recognized in the 3D printed model by a porous density additive manufacturing method. Conclusions: The application of 3D-printing to reproduce a porous structure, such as that of a bone, makes it possible to obtain physical anatomical models that likely represent the internal structure of a bone tissue. This process is low cost and easily reproduced.

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Early Tibial Component Fractures in a Cementless, 3D-Printed, Titanium Implant

Cited by 7 publications

References 23 publications

Oxide degradation precedes additively manufactured Ti‐6Al‐4V selective dissolution: An unsupervised machine learning correlation of impedance and dissolution compared to Ti‐29Nb‐21Zr

Oxide degradation precedes additively manufactured Ti‐6Al‐4V selective dissolution: An unsupervised machine learning correlation of impedance and dissolution compared to Ti‐29Nb‐21Zr

Fretting and Fretting Corrosion Behavior of Additively Manufactured Ti-6Al-4V and Ti-Nb-Zr Alloys in Air and Physiological Solutions

3D-printing of porous structures for reproduction of a femoral bone

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