Detection of cracks in polyethylene components of retrieved knee joint prostheses.

Subsurface cracks that had formed in polyethylene artificial knee components were observed nondestructively with a new method, scanning acoustic tomography (SAT). Standardization of the SAT observation was done by in-vitro rolling fatigue testing on an unimplanted ultra high molecular weight polyethylene (UHMWPE) knee component. Retrieved knee components were of two types; KOM (Kyocera, Kyoto, Japan) sterilized with ethylene oxide gas, and MG (Zimmer, IN, USA) sterilized with gamma-irradiation. The SAT images revealed cracks in all the retrieved components, and these existed mainly 0. 3-1.0 mm from the surface. Comparison of crack formation in each portion of the contact area of the polyethylene components showed that the middle portion of the MG type had the highest concentration of cracks. When the distribution of compressive stress on the polyethylene components was assessed by mechanical testing, the strongest compressive stress was seen in the middle portion of MG type components.