Surface roughness of retrieved CoCrMo alloy femoral components from PCA artificial total knee joints

In this study, we analyzed the surface roughness of retrieved cobalt-chromium-molybdenum (CoCrMo) femoral components of porous coated anatomic (PCA) artificial total knee joints, using a white light interference surface profilometer (WLISP). Thirty-eight PCA retrieved specimens obtained from the Anderson Clinic (Arlington, VA) were used. The artificial knees were originally implanted between 1982-1993, and the specimens were retrieved during revision surgeries between 1988-1996. We examined specimens damaged by three wear modes: femoral component against the ultra high molecular weight polyethylene (UHMWPE) articular surface (mode I), femoral component against the metal tibial tray (because of UHMWPE tibial component wear-through) (mode II), and femoral component against metal-debris-embedded-UHMWPE (with metal debris from the porous coating) (mode III). The mean surface roughness of each femoral component was the average of 80 surface roughness measurements. The in vivo alloy femoral component surfaces were rougher by an order of magnitude over controls, and the alloy surfaces were predominantly worn by the formation of parallel scratches in the direction of articulation. There was no correlation between the surface roughness of the femoral components and patient age, sex, weight, and total time of implantation. Significant surface roughness increases accompanied mode II and mode III wear. Different carbide morphologies were found on different femoral component surfaces, indicating that a variety of sintering processes, with different times and temperatures, may have been applied to the alloy femoral components during manufacture. Metal component roughness may be important to the wear of UHMWPE components and the success of total artificial knee joint.