Squeaking of ceramic-on-ceramic (CoC) hips is a clinical phenomenon that is concerning with regard to the long term performance of these joint devices. Investigations into the cause of the squeaking have focused on patient factors and demographics, surgical placement, and other non-ceramic components in the devices. The current study tests latest-generation CoC devices to measure the vibration modes and frequencies of the components individually as well as assembled in the complete surgical construct.

Audio data from clinical cases of squeaking hips were analysed to determine the frequencies present. Retrieved CoC hips (n = 7) and never-implanted CoC bearing couples (n = 3) were tested in the laboratory for squeaking under loaded articulation.

Bovine serum was introduced into the CoC articulation and dried to promote stick-slip motion at the articulation. Squeaking sounds from the in vitro tests were recorded for audio analysis. Low mass, high frequency-response ceramic shear piezoelectric accelerometers (PCB Piezotronics) were adhered to the hip components along multiple axes to measure vibrations during testing.

Clinical audio shows that squeaking occurs at fundamental frequencies in the range of 1 to 3 kHz, with harmonics above the fundamental frequency. Retrieved CoC bearing couples squeaked at fundamental frequencies from 1.5 kHz to 3.8 kHz. Fourier Transform analysis of the audio closely matched the concurrent output from the accelerometers mounted directly on the ceramic components. This held true even in the absence of metal components in the system. With metal components included in the test construct (acetabular shell, acetabular cup, femoral stem), those components also vibrated at the same frequencies as the ceramic bearing couples, indicating that the CoC articulation is the source of the vibrations, with metal components conducting and emanating the sound.

The never-implanted bearing couples were made to squeak and vibrated at fundamental frequencies ranging from 1 kHz to 8 kHz.

Squeaking from CoC hips can be reproduced in the lab using components from clinical retrievals. Instrumentation of the explanted hips confirms that the vibration frequencies of the ceramic components themselves match the audible squeaking. The squeaking of ceramic components mounted with soft polymers and with no metal contact at any point indicates that the ceramic components themselves are the source of the clinical squeaking. The measured vibration of ceramic components in the audible range is an observation not predicted by modeling studies reported in the literature to date.

Irradiation cross-linking of UHMWPE has been shown to reduce wear while generating free radicals that oxidise in the presence of oxygen or oxidising species. Various methods have been used to minimise or eliminate the effect of these free radicals including below-melt annealing, remelting, Vitamin E infusion, or the use of other antioxidants. Each method has benefits and drawbacks with respect to wear properties, mechanical properties, and chemical properties. Accelerated aging techniques are used to evaluate the efficacy of new methods in stabilising free radicals in highly cross-linked UHMWPE.

Various procedures have been described for aging standard gamma-air sterilised UHMWPE to produce oxidation levels that represent shelf-aged bearings. An important factor in evaluating and comparing these aging techniques is validating that they reproduce the profile of oxidation (depth and magnitude) seen both in gamma-air, shelfaged polyethylene and in clinical retrievals. Moreover, the resulting oxidation level in the aged UHMWPE should predict the fatigue and/or wear damage seen in retrieved gamma-air inserts and liners.

The present study compared clinically relevant UHMWPE samples aged with ASTM 2003-00, (Method B: 70°C, 5 atm O2, 14 days) and a published lower temperature, lower oxygen-pressure environment (63° C, 3 atm O2, 28 days). Longer aging times (35 to 42 days) were also tested to examine oxidation rate and time to onset of mechanical degradation.

Both published methods result in oxidation of gamma-air and gamma-barrier sterilised polyethylene, but have little effect on remelted or antioxidant stabilised crosslinked polyethylene. These aging protocols, however, did not bring standard polyethylene to the critical oxidation level necessary for the fatigue damage that is seen in retrieved inserts and liners.

Oxidation of gamma-air and gamma-barrier sterilised UHMWPE increases exponentially with time on the shelf or in the two aging environments. Of note, longer aging times (35 to 42 days) that bring standard UHMWPE to sufficiently high oxidation levels for fatigue to occur also cause increased oxidation levels in remelted UHMWPE.

Oxidation increases were the smallest in antioxidant UHMWPE, though still detectable.

While this oxidation is not high enough in remelted material or antioxidant material to cause the fatigue damage seen in gamma-air sterilised UHMWPE, it does raise concerns about the published aging techniques and the long term stability of the new materials in vivo.

Relying on artificial aging techniques that do not adequately challenge even gamma-air polyethylene may conceal unforeseen weaknesses of new materials. Using longer aging times for existing techniques or novel aging approaches may be necessary to effectively evaluate the long term stability of new bearing materials.