Zirconia ageing is related to total hip arthroplasty aseptic loosening. A study of 45 retrieved zirconia heads.

Orthop Traumatol Surg Res

Univ Jean Monnet, INSERM, Mines Saint-Étienne, U1059 SAINBIOSE, 42270 Saint-Étienne, France; Mines Saint-Etienne, INSERM, U1059 SAINBIOSE, Univ Jean Monnet, 42270 Saint Etienne, France.

Published: December 2024

AI Article Synopsis

  • The FDA recalled Y-TZP zirconia heads in 2001 due to early material failures linked to defects from tunnel furnace sintering, leading to a halt in zirconia use in orthopedics; however, zirconia grains in ZTA matrices still necessitate investigation into their in vivo aging.
  • A study of 45 batch furnace sintered zirconia femoral heads found a significant phase transition from tetragonal to monoclinic zirconia, correlating this change with increased roughness and a risk of aseptic loosening when the monoclinic phase exceeded 24.5%.
  • The findings suggest that zirconia aging can contribute to complications in joint replacements, indicating a need for

Article Abstract

Background: Y-TZP zirconia heads were recalled by the Food and Drug Administration (FDA) in 2001 and zirconia alone was no longer used in orthopedics. Tunnel furnace sintering was suspected of producing defects responsible for early material failure. As Zirconia Toughened Alumina (ZTA) matrices are widely used as bearing material and contain zirconia grains, there remains a need to better understand the in vivo ageing process of zirconia and its clinical implications when the material is produced by batch furnace sintering, the validated sintering process.

Questions/objectives: Is there an association between the ageing of batch furnace produced zirconia and THA revision?

Methods: 45 retrieved femoral heads, batch furnace sintered only, were analyzed. Roughness was measured by 3D profilometry, phase transfer by μRaman spectroscopy. Clinical data were compared with material characteristics.

Results: Irrespective of the cause of revision, all heads showed a crystallographic phase transition from tetragonal to monoclinic over 19.5%. A correlation was found between the phase change, roughness increase and aseptic loosening, with a threshold set at 24.5% of monoclinic phase.

Conclusions: The ageing process of zirconia may lead to aseptic loosening, which, in the absence of contrary evidence, prohibits its use as the sole component of orthopedic materials. ZTA matrices should be clinically monitored, especially in young patients, and better in vitro modelling needs to be performed.

Level Of Evidence: IV; Case series.

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Source
http://dx.doi.org/10.1016/j.otsr.2024.103991DOI Listing

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