Pre‐clinical evaluation of fretting‐corrosion at stem‐head and stem‐cement interfaces of hip implants using in vitro and in silico models

Abstract Prior to clinical use, the corrosion resistance of new prosthesis system must be verified. The fretting‐corrosion mechanisms of total hip arthroplasty (THA) implants generate metal debris and ions that can increase the incidence of adverse tissue reactions. For cemented stems, there are at least two interfaces that can be damaged by fretting‐corrosion: stem‐head and stem‐cement. This investigation aimed to evaluate, through in vitro and in silico analyses, fretting‐corrosion at the stem‐head and stem‐cement interfaces, to determine which surface is most affected in pre‐clinical testing and identify the causes associated with the observed behavior. Unimodular stems and femoral heads of three different groups were evaluated, defined according to the head/stem material as group I (SS/SS), group II (CoCr/SS), and group III (CoCr/CoCr). Seven pairs of stems and heads per group were tested: three pairs were subjected to material characterization, three pairs to in vitro fretting‐corrosion testing, and one pair to geometric modeling in the in silico analysis. The absolute area of the stem body degraded was more than three times higher compared with the trunnion, for all groups. These results were corroborated by the in silico analysis results, which revealed that the average micromotion at the stem‐cement interface (9.65–15.66 μm) was higher than that at the stem‐head interface (0.55–1.08 μm). In conclusion, the degradation of the stem‐cement interface is predominant in the pre‐clinical set, indicating the need to consider the fretting‐corrosion at the stem‐cement interface during pre‐clinical implant evaluations.