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Predicting deterioration phenomena at coating/implant interfaces in-vivo

English title Predicting deterioration phenomena at coating/implant interfaces in-vivo
Applicant Hauert Roland
Number 156085
Funding scheme Project funding (Div. I-III)
Research institution Eidg. Materialprüfungs- und Forschungsanstalt (EMPA)
Institution of higher education Swiss Federal Laboratories for Materials Science and Technology - EMPA
Main discipline Material Sciences
Start/End 01.09.2015 - 31.08.2019
Approved amount 277'053.00
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All Disciplines (2)

Discipline
Material Sciences
Biomedical Engineering

Keywords (6)

DLC; Joint; Implant; Failure; Coating; Delamination

Lay Summary (German)

Lead
Bei künstlichen Gelenken wie Knie-, Bandscheiben- und Hüftgelenken begrenzt der Materialabrieb die Lebensdauer auf 15 bis 40 Jahre und in einigen Fällen führt er zu unerwünschten Körperreaktionen. Insbesondere zeigt ein zunehmender Teil der Bevölkerung allergische Reaktionen gegen metallischen Abrieb. Wir konnten zeigen, dass mit DLC (Diamond Like Carbon) Beschichtungen ein Gelenkabrieb von praktisch Null und eine Lebensdauer von weit über 100 Jahren erreicht werden könnte. Problematisch sind jedoch Zwischenschichten und Grenzflächen da hier Atome der Beschichtung eine Bindung mit dem Implantat eingehen. Diese Atome sind dann chemisch in einem anderen Zustand und können durch Korrosionsprozesse in Körperflüssigkeit langsam geschädigt werden, was nach Jahren zum Ablösen der Schicht und einem Totalversagen des Gelenkes führen kann.
Lay summary

Inhalt und Ziel des Forschungsprojektes

Ziel des Projektes ist es die Mechanismen der Grenzflächen-Korrosion, -Ermüdung und -Alterung zu verstehen um damit dann die Lebensdauer von beschichteten Implantaten schon vor deren Implantation vorauszusagen. Dazu sollen neue Testverfahren entwickelt werden, welche die Geschwindigkeit von langsamen Schädigungsmechanismen an den nur wenige Atomlagen dicken Grenzflächen genau bestimmen können. Dies ist insbesondere die Spannungsrisskorrosion, ein Phänomen das nur bei Vorhandensein von Spannung und in einem korrosiven Medium stattfindet. Auch die Bestimmung von Spaltkorrosion ist äussert herausfordernd, da sich dieser Effekt kaum beschleunigen lässt aber schon mehrmals die Ursache für das Versagen von künstlichen Gelenken nach 5 bis12 Jahren im Körper wahr.

 

Wissenschaftlicher und gesellschaftlicher Kontext des Forschungsprojektes

Ein Verfahren um die Lebensdauer von Grenzflächen in korrosiven Medien, wie Körperflüssigkeit, vorherzusagen wäre ein wissenschaftlicher Durchbruch. Die Entwicklung von neuen, abriebfreien Gelenkimplantaten mit über 100 Jahren Lebensdauer wäre eine medizinische Sensation, von welcher vor allem auch jüngere Patienten profitieren würden.

Direct link to Lay Summary Last update: 01.07.2015

Responsible applicant and co-applicants

Employees

Name Institute

Publications

Publication
A methodology for characterizing the electrochemical stability of DLC coated interlayers and interfaces
Ilic Emilija, Pardo Ainhoa, Suter Thomas, Mischler Stefano, Schmutz Patrik, Hauert Roland (2019), A methodology for characterizing the electrochemical stability of DLC coated interlayers and interfaces, in Surface and Coatings Technology, 375, 402-413.
Silicon Corrosion in Neutral Media: The Influence of Confined Geometries and Crevice Corrosion in Simulated Physiological Solutions
Ilic Emilija, Pardo Ainhoa, Hauert Roland, Schmutz Patrik, Mischler Stefano (2019), Silicon Corrosion in Neutral Media: The Influence of Confined Geometries and Crevice Corrosion in Simulated Physiological Solutions, in Journal of The Electrochemical Society, 166(6), C125-C133.
Delayed delamination mechanisms of DLC coatings on articulating implants
Ilic Emilija, PardoAinhoa, HauertRoland, SchmutzPatrik, MischlerStefano (2019), Delayed delamination mechanisms of DLC coatings on articulating implants, in eCM Online Periodical, 2019, , 2-2.
Corrosion fatigue in DLC-coated articulating implants: an accelerated methodology to predict realistic interface lifetime
Pardo Ainhoa, Ilic Emilija, Thorwarth Kerstin, Stiefel Michael, Hauert Roland (2019), Corrosion fatigue in DLC-coated articulating implants: an accelerated methodology to predict realistic interface lifetime, in Science and Technology of Advanced Materials, 20(1), 173-186.
Accelerated tests for coating adhesion lifetime estimation in body fluid
Hauert Roland, IliicEmilija, Pardo-PerezAinhoa, SchmutzPatrik, MischlerStefano (2018), Accelerated tests for coating adhesion lifetime estimation in body fluid, in eCM Online Periodical, 2018, 7-7.
Lifetime Estimation of Coated Articulating Implants: accelerated testing to address crevice, stress and fatigue corrosion
Ilic Emilija, PardoAinhoa, HauertRoland, SchmutzPatrik, MischlerStefano (2018), Lifetime Estimation of Coated Articulating Implants: accelerated testing to address crevice, stress and fatigue corrosion, in eCM Online Periodical, 2018, 1-1.

Collaboration

Group / person Country
Types of collaboration
EPFL Switzerland (Europe)
- in-depth/constructive exchanges on approaches, methods or results
- Publication
- Research Infrastructure
- Exchange of personnel

Scientific events

Active participation

Title Type of contribution Title of article or contribution Date Place Persons involved
Swiss Medtech Day 2019 Poster Interface Stability Assessment and Engineering of Coated Im-plants 06.06.2019 Bern, Switzerland Illic Emilija; Mischler Stefano; Schmutz Patrik; Hauert Roland;
Meet the Expert - Implants 2019 Poster Delayed delamination mechanisms of DLC coatings on ar-ticulating implants 19.03.2019 Olten, Switzerland Mischler Stefano; Hauert Roland; Schmutz Patrik; Illic Emilija;
EuroCorr 2018 Talk given at a conference Crevice corrosion investigations of silicon in simulated body fluid conditions 09.09.2018 Krakau, Poland Hauert Roland; Schmutz Patrik; Illic Emilija; Mischler Stefano;
Meet the Expert - 2018 Poster Lifetime estimation of coated articulating implants 13.03.2018 Olten, Switzerland Illic Emilija; Schmutz Patrik; Mischler Stefano; Hauert Roland;
EuroMat 2017 Talk given at a conference Delayed delamination mechanisms of DLC coatings on articulating implants 17.09.2017 Thessaloniki, Greece Mischler Stefano; Schmutz Patrik; Illic Emilija; Hauert Roland;
EuroCorr 2017 Talk given at a conference Crevice and stress corrosion cracking of DLC coated implant interlayers 03.09.2017 Prag, Czech Republic Hauert Roland; Illic Emilija; Schmutz Patrik; Mischler Stefano;
SAOG Meeting 2017 Poster Predicting deterioration phenomena at coating/substrate interfaces 27.01.2017 Fribourg, Switzerland Hauert Roland; Mischler Stefano; Illic Emilija; Schmutz Patrik;
Junior EuroMat 2016 Poster Delayed delamination mechanisms of diamond-like carbon coatings on articulating biomedical implants 10.07.2016 Lausanne, Switzerland Schmutz Patrik; Mischler Stefano; Illic Emilija; Hauert Roland;


Self-organised

Title Date Place
CORROSION MECHANISMS OF DLC COATING/SUBSTRATE INTERFACES (Public Defence) 23.09.2019 Dübendorf, Switzerland

Associated projects

Number Title Start Funding scheme
182987 Hard X-ray Photoelectron Spectrometer with environmental processing chamber for depth-resolved chemical-state analysis of functional thin films and their buried interfaces 01.11.2019 R'EQUIP
171412 Lifetime prediction of coated implants: study of time and loading dependent local deterioration mechanisms at interfaces and critical degrading effects 01.02.2017 Marie Heim-Voegtlin grants

Abstract

The target of this project is to analyze and understand the scientific principles of local deterioration mechanisms in confined electrolytes and to identify critical effects acting on the few atomic rows of reactively formed material at a coating/substrate interface. With this knowledge and the new electrochemical setups that will be built, we will gain the ability to predict the adhesion lifetime of coated parts (for example, coated artificial joint implants) which are in use for a much longer time period than they can be tested. The innovative aspects of research consist of detailed analysis of the electrochemical reaction induced chemistry generated at the interface, and the design and construction of experimental setups with very high current detection sensitivity allowing a quantitative determination of all interface degrading effects acting on a few atomic layers. These are mainly extremely slow crack advancements or very slow material dissolution by SCC (stress corrosion cracking), CC (Crevice Corrosion), passive surface oxide dissolution, fatigue or corrosion fatigue. Our considered approach is opposite to investigations on coating adhesion usually neglecting all very slowly advancing and time dependent effects acting on the interface. Artificial joint simulator tests, which are required prior to implantation, are accelerating typically only the phenomena which run as a function of articulation cycles and ignoring interface corrosion related phenomena slowly running as a function of time. This will then lead to false implant lifetime predictions for coated implants. In the last decades several series of DLC (diamond-like carbon) coated implants, which initially showed good results, still failed after 3-12 years in the patients mainly due to coating delamination. Today, no setups or procedure is known which is capable of predicting the interface lifetime of a coated material in a corrosive media, such as body fluid or ambient humid air based on scientific assessment of local “electro”chemical reaction rates
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