In vitro wear rate and Co ion release of compositionally and structurally graded CoCrMo-Ti6Al4V structures

Novel, unitized structures with porous Ti6Al4V alloy on one side and compositionally graded, hard CoCrMo alloy surface on the other side have been fabricated using laser engineered net shaping (LENS (TM)) process. Gradient structures with 50%, 70% and 86% CoCrMo alloy on the top surface showed a high hardness in the range of 615 and 957 HV. The gradient structures were evaluated for their in vitro wear rate and Co release up to 3000 m of sliding distance. The wear rate of ultrahigh molecular weight polyethylene and 100% CoCrMo alloy substrates was found to depend on the hardness and microstructural features of the counter surface rubbing against them. In general, the wear rate of both the substrates increased with a decrease in the CoCrMo alloy concentration on the top surface of gradient pins. However, the wear rate of gradient pins was lower than 100% CoCrMo alloy pins due to their high hardness. Lowest wear rate in the range of 5.07 to 7.99 x 10(-8) mm(3)/Nm was observed for gradient pins having 86% CoCrMo alloy on the top surface. The amount of Co released, in the range of 0.38 and 0.91 ppm, during in vitro wear testing of gradient structures was comparable to that of 100% CoCrMo alloy (0.25 and 0.77 ppm). Present unitized structures with open porosity on one side and hard, wear resistant surface on the other side can minimize the wear-induced osteolysis and aseptic loosening, and eliminate the need for multiple parts with different compositions for load-bearing implants such as total hip prostheses. (C) 2010 Elsevier B.V. All rights reserved.