Origins of material loss in highly worn acetabular cups of metal‐on‐metal total hip replacements

Excessive wear has been one of the major failure modes of metal‐on‐metal hip implants. From a collection of 541 retrieved ASR metal‐on‐metal implants, we selected those head‐cup pairs with combined wear >100 mm³, (N = 42) to assess the distributions of wear volume on cups, and non‐conformance in the worn areas at the head‐cup interfaces. All 42 had severe cup edge wear (average maximum wear depth 500 μm). On average, 58% of wear volume of cups occurred at the edge areas, whereas 42% occurred well inside the socket, indicating that substantial wear volume of cups was generated well inside the socket. Particularly, in eight cups, more than half of the wear volume occurred well inside the socket. The head‐cup conformance in the worn areas was deteriorated. On average, in worn areas, head‐cup clearance was approximately eight times greater than in unworn areas, and the sphericity of heads and cups was approximately 36 times and 84 times higher, respectively, than in unworn areas. The radius of curvature of the worn surfaces of heads and cups varied widely, with an average variation of 3 mm (0.6–7 mm) and 11 mm (2–47 mm) for heads and cups, respectively. The severely deteriorated conformance at the edge areas and the areas well inside the socket, due to edge contact, could be the major factor for excessive wear of these 42 pairs.