Effect of crosslinking, remelting, and aging on UHMWPE damage in a linear experimental wear model.

The objective of this study was to establish the effect of postirradiation melting as a function of irradiation dose on the wear behavior and material characteristics of ultrahigh molecular weight polyethylene. Our hypothesis was that a low dose of irradiation followed by melting would have the same improved wear performance as is found with higher doses of irradiation, but without the disadvantages associated with reduced fracture toughness. The hypothesis was tested by measuring the wear performance (wear track area, incidence of pitting and delamination) in a linear doubly curved-on-flat cyclic test, material behavior (elastic modulus, fracture toughness), and aging response (density changes through the thickness) of the following materials: elevated crosslinked groups--radiated at 25, 65, and 120 kGy, melted, sterilized and aged; a melted group--melted, sterilized, and aged; and a control group--sterilized and aged. Our findings suggest that postirradiation melting, not the irradiation dose, dominates the material property changes and wear response. Melting ensured reduced modulus and therefore decreased contact stresses, superior wear performance, and good resistance to aging, even after low levels of irradiation (25 kGy). The low modulus of the 25 kGy elevated crosslinked group, coupled with increased fracture toughness compared to samples irradiated at higher doses and a resistance to aging not found in the melted group, support our hypothesis. A low dose of irradiation followed by heat treatment has the same beneficial effects in terms of improved wear performance, but without the disadvantages of reduced fracture toughness found with higher doses of irradiation.