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Variability in CoCrMo alloy microstructure, particularly banded structures in wrought alloys, can increase corrosion and metal ion release, raising the risk of adverse local tissue reactions (ALTRs) after total hip arthroplasty (THA).

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Area of Science:

  • Biomaterials Science
  • Orthopedic Surgery
  • Materials Science

Background:

  • Adverse local tissue reactions (ALTRs) from corrosion products in modular taper junctions are a common cause of premature total hip arthroplasty (THA) failure.
  • Cobalt-chromium-molybdenum (CoCrMo) alloys are of particular concern due to linked cobalt and chromium-orthophosphate ions contributing to ALTRs.
  • Microstructural differences between cast and wrought CoCrMo alloys and their impact on corrosion are not well understood.

Purpose of the Study:

  • To determine if cast CoCrMo alloy microstructure varies between manufacturers and influences specific corrosion modes.
  • To assess if wrought CoCrMo alloy microstructure is consistent and has low implications on corrosion behavior.

Main Methods:

  • Metallographic and electrochemical characterization of cast and wrought CoCrMo alloy samples from retrieved THA components.
  • Potentiodynamic polarization (PDP) tests to measure corrosion potential (Ecorr), corrosion current density (Icorr), and pitting potential (Epit).
  • Statistical analysis (ANOVA, t-tests) to compare PDP metrics based on manufacturer and microstructural features (hard phases, banding).

Main Results:

  • Broad microstructural variability was observed in both cast and wrought CoCrMo alloys, even within the same implant design.
  • Cast alloys with coarse or clustered hard phases showed increased phase boundary and pitting corrosion, with a lower pitting potential.
  • Wrought alloys with banded structures exhibited lower corrosion potential and higher corrosion current density, indicating unfavorable corrosion behavior.

Conclusions:

  • Variability in CoCrMo alloy microstructure is a significant issue that requires better standardization to minimize in vivo corrosion and metal ion release.
  • Banded structures in wrought alloys are particularly concerning, negatively impacting corrosion independent of the manufacturer.
  • Homogeneous microstructures with minimal hard phases appear to offer more favorable corrosion resistance, potentially reducing ALTR risk.