Subsurface changes of a MoM hip implant below different contact zones

Metal-on-metal hip arthroplasties undergo distinct release of toxic metal particles and ions. Thus, it is necessary to minimize this. In order to evaluate the wear behaviour of metal-on-metal hip replacements it is essential to understand the micro-structural changes in the sub-surface region. Previous studies revealed that cobalt chromium metal-on-metal implants are able to alter their mechanical behaviour by adjusting the microstructure to load. The reason for this is the so-called mechanical mixing. This means that a nano-crystal layer is formed by rotating clusters of atoms that incorporate denatured proteins from the interfacial medium. This is followed by a layer of rhombic shaped nano-crystals in between sheared epsilon-martensite lathes, twins, and stacking faults. Although the primary wear zone has been well characterized, the sub-surface structure of the stripe wear and the non-contact zone of the hip ball have yet to be analysed. For this study a 28-mm cobalt base alloy femoral head and acetabular cup were analysed. The implant was simulator tested for 5 million cycles with the application of micro-separation resulting in a clearly visible stripe wear appearance. The TEM micrograph of the primary wear zone of the ball confirmed the presence of a sub-surface layer of nano-crystals. The thickness of this layer was approximately 200 nm and the average grain diameter ranged from 35 to 40 nm. Within the stripe wear zone the micrographs also revealed a nano-crystal layer but with a thickness of only 50 nm and an average grain diameter from 15 to 20 nm. The carbon and oxygen content was highest closest to the surface which proves the occurrence of mechanical mixing. The non-contact zone of the ball was analysed as well. When compared to the primary wear zone a nano-crystal layer with similar thickness but with an average grain diameter smaller than 15 nm was observed.