Hip and knee joint replacements are common and largely successful procedures that utilise implants to restore mobility and relieve pain for patients suffering from e.g. osteoarthritis. However, metallic ions and particles released from both the bearing surfaces and non-articulating interfaces, as in modular components, can cause hypersensitivity and local tissue necrosis, while particles originating from a polymer component have been associated with aseptic loosening and osteolysis. Implant coatings have the potential to improve properties compared to both bulk metal and ceramic alternatives. Ceramic coatings have the potential to increase scratch resistance, enhance wettability and reduce wear of the articulating surfaces compared to the metallic substrate, whilst maintaining overall toughness of the implant ensuring a lower risk of catastrophic failure of the device compared to use of a bulk ceramic. Coatings can also act as barriers to inhibit ion release from the underlying material caused by corrosion. This review aims to provide a comprehensive overview of wear-resistant coatings for joint replacements - both those that are in current clinical use as well as those under investigation for future use. While the majority of coatings belong predominantly in the latter group, a few coated implants have been successfully marketed and are available for clinical use in specific applications. Commercially available coatings for implants include titanium nitride (TiN), titanium niobium nitride (TiNbN), oxidized zirconium (OxZr) and zirconium nitride (ZrN) based coatings, whereas current research is focused not only on these, but also on diamond-like-carbon (DLC), silicon nitride (SiN), chromium nitride (CrN) and tantalum-based coatings (TaN and TaO). The coating materials referred to above that are still at the research stage have been shown to be non-cytotoxic and to reduce wear in a laboratory setting. However, the adhesion of implant coatings remains a main area of concern, as poor adhesion can cause delamination and excessive wear. In clinical applications zirconium implant surfaces treated to achieve a zirconium oxide film and TiNbN coated implants have however been proven comparable to traditional cobalt chromium implants with regards to revision numbers. In addition, the chromium ion levels measured in the plasma of patients were lower and allergy symptoms were relieved. Therefore, coated implants could be considered an alternative to uncoated metal implants, in particular for patients with metal hypersensitivity. There have also been unsuccessful introductions to the market, such as DLC coated implants, and therefore this review also attempts to summarize the lessons learnt.

The Stationary Shoulder Friction Stir Welding (SS-FSW) technique benefits from reduced heat input, improved mechanical properties and surface finish of the weld, avoiding the need for post weld processing. Coatings on the tool probe and the shoulder for welding of aggressive Aluminium alloys have rarely been successful. Such coatings must be well adherent and inert. In this study, coated tools were used for SS-FSW of AA6082-T6 alloy. Performance of a nanoscale multilayer TiAlN/VN coating deposited by High Power Impulse Magnetron Sputtering (HIPIMS) technology was compared with amorphous Diamond Like Carbon (a-C:H) by Plasma Assisted Chemical Vapour Deposition (PACVD), AlTiN deposited by arc evaporation and TiBCN along with TiB2 produced by Chemical Vapour Deposition (CVD) methods. The TiAlN/VN coating was found to have low affinity to aluminium, acceptable coefficient of friction and provided excellent weld quality by inhibiting intermixing between the tool and workpiece materials resulting in a significant reduction in tool wear.

Clinical studies have found high wear rates, elevated ion levels and high revision rates of large-diameter metal-on-metal surface replacement bearings in some patients, which have been associated with edge loading of the head on the rim of the cup. We have simulated increased wear and ion levels in metal-on-metal bearings in vitro by introducing variations in translational and rotational positioning of the components, which reproduces stripe wear on the femoral head, cup rim wear and clinically relevant large as well as small wear particles. There is interest in technologies such as surface engineering, which might reduce metal wear and the release of wear particles and ions. Reduced wear with surface-engineered surface replacements compared to metal-on-metal controls has been reported under standard walking conditions with correctly aligned and concentric components. In this in vitro study, the wear of chromium nitride surface-engineered metal-on-metal bearings under conditions of microseparation associated with translational and rotational malpositioning of the components was investigated and the results were compared with a previously reported study of metal-on-metal bearings under the same conditions. Simulations were conducted using our unique hip simulation microseparation methodologies, which reproduce accelerated wear in metal-on-metal bearings and have previously been clinically validated with ceramic-on-ceramic bearings.Four of the six surface-engineered bearings had evidence of head contact on the rim of the cup, which produced stripe wear on the femoral head. Four of the six surface-engineered bearings (two without stripe and two with stripe wear) had lower wear than the previously reported high wearing metal-on-metal bearings. At 2 million cycles, two of the surface-engineered bearings had substantially increased wear rates, four times higher than the high wear rates previously reported for metal-on-metal bearings under the same conditions. There was wear through and cohesive failure of the thick atomic emission physical vapour deposition (AEPVD) chromium nitride (CrN) coating. At this point, the study was stopped to investigate the failure mode.This study highlights the need to pre-clinically investigate the tribology of new bearings under a wide set of clinical conditions as demonstrated by our stratified approach for enhanced reliability (SAFER) simulation methods. In adopting this SAFER approach to pre-clinical simulation testing of new bearings, it is important to communicate the failures as well as successes of technologies arising from the research, in order that the wider community can benefit from the analysis of the pre-clinical failure modes.

This paper presents a new group of nanocomposite coatings based on integrating inorganic fullerene-like material (IFLM) structures into conventional coating matrices. Such coatings have been developed within the scope of the European funded FOREMOST project (FP6-NMP3-CT-2005-515840).Regarding the synthesis of these nanocomposite coatings based on fullerene-like components, two alternative routes were explored: introducing preformed IFLMs into the coating deposition process or forming the fullerene-like components in situ during the coating deposition process. Both methods have been demonstrated to be technically feasible, depending on the nature of the coating matrix or the desired fullerene-like structure.These new materials allow some independent control of tribological properties usually known as antagonists (very high load bearing capacity with a very low friction coefficient). In the case of unidirectional movement, under dry conditions, the best coatings developed in FOREMOST displayed a coefficient of friction in air within the range 0.04-0.10, depending on the degree of humidity and the test conditions. Pure sliding laboratory tests indicate that for some industrial applications fullerene-like nanocomposite coatings can give significant reductions in wear and friction coefficient when compared to similar coatings without fullerene-like components. The lubrication mechanisms through which these fullerene-like structures improve friction and prevent wear are also discussed in this paper. (C) 2011 Elsevier Ltd. All rights reserved.

This paper presents the outcomes from a workshop of the European Network on the Health and Environmental Impact of Nanomaterials (NanoImpactNet). During the workshop, 45 experts in the field of safety assessment of engineered nanomaterials addressed the need to systematically study sets of engineered nanomaterials with specific metrics to generate a data set which would allow the establishment of dose-response relations. The group concluded that international cooperation and worldwide standardization of terminology, reference materials and protocols are needed to make progress in establishing lists of essential metrics. High quality data necessitates the development of harmonized study approaches and adequate reporting of data. Priority metrics can only be based on well-characterized dose-response relations derived from the systematic study of the bio-kinetics and bio-interactions of nanomaterials at both organism and (sub)-cellular levels. In addition, increased effort is needed to develop and validate analytical methods to determine these metrics in a complex matrix.

Increased patient blood and serum levels of Co and Cr and dissemination of metal wear particles throughout organs and tissues are the primary concerns with metal-on-metal surface replacements. Surface engineering, providing a ceramic bearing surface on a metal substrate, could provide a solution. This study investigated thick (>10 microm) arc evaporation plasma vapor deposition chromium nitride (CrN) coated surface replacements in terms of wear, ion levels, and wear particles in a 10 million cycle hip simulator study, compared to a contemporary metal-on-metal surface replacement. The ion levels were measured by inductively coupled plasma mass spectroscopy. The wear particles were imaged by field emission gun scanning electron microscopy. The CrN-coated bearings had 80% lower wear than the MoM controls. The Cr and Co ion levels in the lubricant of the CrN bearings were 73 and 98% lower than in the MoM controls. The wear particles produced were in the nanometer size range and round to oval in morphology. The CrN coating could provide a reduction in the wear and ion release of MoM surface replacements, thereby reducing the perceived risks to the patient associated with these prostheses.

WS2 fullerene particles and nanotubes show a diameter and morphology dependent Raman response, see figure showing response for WS2 nanotubes of 290 nm and 50 nm diameter. This enables the classification of WS2 nanotubes, fullerenes, and nanocrystals, and the estimation of geometric properties. Detailed facts of importance to specialist readers are published as ”Supporting Information”. Such documents are peer-reviewed, but not copy-edited or typeset. They are made available as submitted by the authors. Please note: The publisher is not responsible for the content or functionality of any supporting information supplied by the authors. Any queries (other than missing content) should be directed to the corresponding author for the article.

Over 80% of artificial hip joints utilise polyethylene acetabular cups articulating on metal or ceramic femoral heads. Alumina ceramic heads have previously been shown to reduce polyethylene wear. However, there are concerns about the brittle nature of ceramics and this places design constraints on neck length and head size. It is therefore of interest, to investigate ceramic-like coatings on metallic heads. The aim of this study was to compare the wear of polyethylene against alumina ceramic and chromium nitride (CrN) coated CoCr femoral heads in a hip joint simulator.