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Biomechanical Behavior of a Variable Angle Locked Tibiotalocalcaneal Construct.

Farah Hamandi1, Gerard Simon2, Richard Laughlin3

  • 1Department of Biomedical, Industrial and Human Factors Engineering, Wright State University, Dayton, OH 45435, USA.

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Summary

This study investigated a failed PHILOS plate system, revealing corrosion-fatigue and overload as failure mechanisms. Material inconsistencies in the Stainless Steel 316L construct contributed to the mechanical failure of the tibiotalocalcaneal construct.

Keywords:
crackfinite elementlocking platelocking screwnonlocking screwpitting

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Area of Science:

  • Orthopedic biomechanics
  • Materials science and engineering
  • Failure analysis

Background:

  • The tibiotalocalcaneal construct is crucial for hindfoot reconstruction.
  • PHILOS plating systems are commonly used, but their failure modes require thorough investigation.
  • Understanding implant failure is vital for improving patient outcomes and device design.

Purpose of the Study:

  • To analyze the failure mechanisms of a specific PHILOS plating system used in a tibiotalocalcaneal construct.
  • To identify the contributing factors to the mechanical failure of the plate and screws.
  • To correlate material properties and manufacturing standards with observed failure modes.

Main Methods:

  • Visual, microstructural, and fractographic examinations of the failed implant.
  • Material characterization including crystallography and texture analysis.
  • Finite element modeling (FEM) to simulate failure conditions and boundary conditions.

Main Results:

  • Fracture surfaces exhibited scratching, inclusions, discoloration, corrosion pits, beach marks, cleavage, and striations.
  • S, Ni, and Mo-based inclusions in Stainless Steel 316L likely increased susceptibility to pitting corrosion.
  • Failure resulted from a combination of pitting corrosion-fatigue and final overload, with screws failing by bending and torsion fatigue.

Conclusions:

  • The PHILOS plate failure was attributed to a corrosion-fatigue mechanism exacerbated by material inconsistencies (chemistry, hardness) violating ASTM F138-8/ISO 5832 standards.
  • Overloading contributed to the final fracture of the plate and screws.
  • FEM simulations successfully replicated the observed failure conditions, validating the analysis.