In vitro test methods for seating and fretting corrosion behavior of modular metal-on-metal acetabular tapers.

Retrieval studies show that metal-on-metal acetabular shell-liner tapers are susceptible to corrosion, which is hypothesized to arise from mechanically-assisted crevice corrosion (MACC). The role of materials on MACC of acetabular tapers has not been previously studied. In vitro tests of seating, pushout, and fretting corrosion performance of acetabular tapers are presented to assess the role of material combinations (Ti-6Al-4V shells, HC CoCrMo, LC CoCrMo, and 316L SS liners). The acetabular tapers were wet-assembled to a seating load of 1,000 N. The liner load-displacement seating mechanics were measured. Fretting corrosion currents were evaluated using a uniaxial incremental cyclic compression test up to 4,000 N, with the load applied at a 55° angle to the taper interface. Fretting currents, fretting onset loads, taper disengagement strength were measured and load-displacement plots were obtained. Pushout tests were also performed pre- and post-fretting corrosion. The average liner seating displacements varied from 134 to 226 μm across groups. Fretting currents at 3,600 N cyclic load were low and ranged between 0.05 and 0.27 μA and were independent of material combination (p > 0.05), reflecting small amounts of fretting. Fretting corrosion onset loads were between 1,800 and 2,100 N, and did not differ across groups (p > 0.05). Pushout loads were 27-43% of the maximum load applied. Fretting corrosion levels were very low for all material combinations and not different from one another. The seating and pushout responses were also not material dependent. The low fretting currents measured imply that MACC may not be a major cause for acetabular taper corrosion. © 2019 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 38:00-111089, 2020.