Summary of Redesign of Indonesian-made osteosynthesis plates to

enhance their mechanical behavior

In this study, the mechanical properties of an Indonesian-made were enhanced to
be made capable to compete with the mechanical properties of the European
Standard (AO) stainless steel 316L made in Switzerland. The original Indonesianmade stainless steel has a lower overall quality in mechanical properties than those
of the 316L stainless steel made in Switzerland. Shot peening and SMAT-treatment
were the two methods used to enhance the mechanical properties of the
Indonesian-made stainless steel. Specimens in this experiment were taken form of
thin plates with 6 holes in each plate, or so called the Dynamic Compression Plate.
The specimens were grouped into 6 groups:
1.
2.
3.
4.
5.
6.

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Indonesian Manufacturer A
Indonesian Manufacturer A, SMAT treated
Indonesian Manufacturer B
Indonesian Manufacturer B, SMAT treated
Indonesian Manufacturer B, shot peened
Mathys/ Synthes as the standard plate (S)

Each group of plates were tested to study the strength (proportional load limit,
bending stress) and the fatigue limit (Load, bending stress limit).
The results were shown that, during the single cycle bending test, shot peened and
SMAT-treated plates showed improvements in mean failure loads and mean bending
stresses, compared to those of the original A and B plates. SMAT-treated plate from
Manufacturer A exceeded the mean failure load of the standard European plate (S).
None of the modified treated plates from Manufacturer A nor B could exceed the
calculated bending stress of the standard plate (S). The fatigue test of 3 million
cycles were also concluded. SMAT-treated plates from Manufacturer A showed
considerable improvements, resulting in exceeding the fatigue load limit of the
standard plate.
Effects of surface mechanical attrition treatment (SMAT) on a rough
surface of AISI 316L stainless steel
In this study, Surface mechanical attrition treatment (SMAT) were used to smoothen
a rough-surfaced AISI 316L stainless steel material. SMAT modifies the morphology
and the roughness of the specimen. Previous studies have been done on using SMAT
to roughen a smooth surface, but this time is used to smoothen a rough surface. A
variation of size of milling balls were used during this experiment, ranging from
3.18mm to 6.35mm. The modification of subsurface micro hardness, surface
morphology, roughness, and mass reduction were taken into account. The specimen
were formed into steel strips or plates with a dimension of 100mm x 50mm x 4mm.
A clean-up procedure were taken into action using 70% ethanol solution to remove
impurities at the surface. The specimen was placed in a tubular chamber with a
dimension of 150mm in length and 80mm in diameter containing 250 milling balls
of various size. The SMAT was carried out by shaking the chamber for 20 minutes
with a rotational speed of 1400rpm.

A test of Vickers Indentation were tested on the specimen to determine the

hardness of the surface. The indentation was made with an applied load of 4.9N and
depth of 0.1mm below the surface material. After the indentation, a SEM study was
conducted using XL 30 ESEM to inspect the morphology of the surface.
The results were shown that an improvement in hardness occurred, an increased
value of 2.9GPa from a previous non treated hardness value of 1.6 GPa. The surface
of the material has become smoother, as the peak-to-valley heights decrease after
the treatment.
High Temperature fatigue test of notched specimens made of titanium
Grade 2
In this study, a uniaxial-tension load fatigue test were done on titanium grade 2
specimens on two different temperatures, at room temperature and at 500 Celsius.
The specimens were formed into two shapes of geometry, tension bar with
semicircular notches and plates with symmetric V-notches. Titanium has a widespread application. It has been recognized for its strategic mechanical properties as
a lightweight, high strength, high-performance, and an anti-corrosion material. The
researchers in this study are interested in its consistency in strength during raised
temperatures. A test at a temperature of 500 Celsius was chosen because, by the
authors knowledge, only a limited number of works dealing with high-temperature
fatigue are available in the literature and no results seem to be available from
notched components made of Titanium Grade 2.
The results were concluded that:

Titanium Grade 2 has a good fatigue behavior in high temperature

applications
The microstructures were in general homogeneous and showed little or no
grain degradation during long exposures on high temperature.
The specimen tested at 500 Celsius presents more voids than the specimen
tested at Room Temperature
During a 2 million cycle fatigue test, the semicircular notched specimen were
subjected to 142MPa and to 84MPa at room temperature and at 500C
respectively in that order. The V-notched plates were subjected to a stress
range to 57MPa and 54.96MPa at room temperature and 500C respectively.
Another conclusion can be made, that even though, the V-notched plates
have less fatigue strength than the semicircular tension bar specimens, it is
shown that they are less sensitive to high temperature applications, as seen
above resulting a small difference of stress range at the two applied
temperatures.

Laser and chemical surface modifications of titanium grade 2 for medical

application
This paper presents the study of physical and chemical approach for surface
modifications of titanium grade 2. The physical approach uses the help of double
laser beam technique. The results were characterized in terms of shape, roughness,

chemical composition, mechanical properties and microstructures. To study and

examine the specimens, numerous methods of examination were used, such as
SEM, atomic force microscopes, optical profilometry and microhardness
measurements. This study was made, in hope to act as an effective method of
manufacturing surface structures for biomedical applications.
Chemical etching is first applied to the specimen to remove oxide, contamination
and to smoothen surface defects remaining. The chemical used are often strong
acids such as HCl, HNO3, etc. The chemical etching was performed within 3 minute
at a room temperature condition, with ultra-sonic vibration applied.
After the chemical etching, laser treatment was performed. The method allows the
formaton of micro and sub-micrometer structures on the surfaces applied. The
intensity of the energy was fixed at 400mJ/cm2 while the wavelengths of the beam
were varied.
The results shown, that the chemical etching procedure removes contaminations
and longitudinal surface defects. The new topography was more uniform (shown by
Figure 2). The DLIL technique leads to well defined parallel grooves. Laser
procedures emphasized the possibility to forming oxide layers on the surfaces. The
formation of oxide layers is considered positive for bio stability. The analysis was
performed and the results showed that DLIL does modify the surface chemical
compositon and so it possesses non uniform oxygen distribution. The lowest
concentration of oxide was found on the bottom of the groove, while the maximum
concentration was found at the summit of the groove. The mechanical properties of
the altered Titanium surface were also examined. Microhardness test were
performed with 50 and 100g loads. The results were shown that an increase of 11.6
to 20% in HV occurred after the DLIL procedure. The hardness enhancement was
caused by the formation of oxide layers on the surface of the specimen that was
formed during the laser activity.
Compressive residual stress introduced by Shot Peening
Shot peening is a surface treatment method of improving the fatigue stress of
materials. Shot peening changes the structures of the surface due to the formation
of residual stress field (RSF) during the process. In this paper, the compressive
residual stress field of several shot-peened metals of different materials were
studied. The materials of the metals studied are 20Cr, 30CrMo, 40Cr, GC4, and
aluminum alloys. The specimens were formed into thin plates of 15x10x50 mm. The
shot peening was done with a pneumatic machine. The steel balls with a hardness
of 44-48 HRC and 0.8mm diameter were used.
The experimental results were analyzed. The compressive residual stress
distributions of the hardened surface layer were measured. For all the specimens,
the residual stress were compressive. The depth to peak value varies depending on
the material of the specimen. Four characteristic parameters have been named and
studied to quantitively describe the CRSF; the compressive residual stress at the
surface, the maximum value of the compressive residual stress, Z mc as the distance
of the maximum value of the CRS from the surface, and Z o as the depth.

Fatigue Analysis of the Knee Joint

The knee is one of the most engaged voluntary part of the body, for it tendency to
move. The constant movement makes it very prone to degradation in aging. The
objective of this study is to model the knee joint and analyze it under varying loads
to get an indication about fatigue life of the joint. The study of the knee joint under
cyclic loads helps predict and know more about the fatigue life. Fatigue analysis can
also help understand the cause of knee joint failures, which would push us further to
design better to avoid these failures.
Using a CT image of a healthy patient and a DICOM viewer, a 3D of the knee joint
have been generated using ANSYS. The mechanical properties of the design were
taken from the mechanical properties of real bones and tendons. The forces applied
to the knee joint were emulated as similar as possible to the forces that would apply
to real knees during daily movements. The static forces applied varied from a range
of 10-1010N. The stress and strain regions, and safety factors were measured. The
stress strain analysis was concluded with the analysis for safety factors, safety
margin, deformation and life.
The results were concluded that:

Under loading, the ligaments and tendons do get strained.

As the force applied is increased, the deformation increases.
As cyclic load magnitude is increased, the life in cycles decreases.
The safety factor and safety margin decreases exponentially as the applied
forces were increased.

In the study it was found that the fatigue life of the knee joint would go down from
1.2 million cycles to 9531 cycles as the force increased from 10N to 1010N.
An experimental approach
polyethylene tibial inserts

to

determining

fatigue

crack

size

in

Each year, 700 thousand knee surgeries are performed in the US to treat
degenerative joint diseases by replacing the damaged natural knee with a
prosthetic knee joint. The performance of the prosthetic knee joint have been
documented to decline dramatically after 15-20 years of usage. The primary reason
of these failures are caused by fatigue wear. Existing methods to locate, and inspect
fatigue crack damage have several shortcomings such as limited resolution,
destructive testing approach, and high cost. In this study, the author propose an
alternative fatigue crack damage visualization and measurement methods that
overcome these shortcomings of the existing methods available. This new method
of inspection is based on trans-illumination. It is a non-destructive method of
inspection and has low-cost set-up.
In this experiment, two tibial inserts are being measured for fatigue crack damage
using the proposed method. Tibial insert 1 is a 7mm thick posterior that was used in
a knee wear simulation, while tibial insert 2 is a 14mm tibial insert that was
retrieved from 9 years of use in vivo. Tibial 1 is tested using a knee simulator, in
accordance with ISO standard 14243-1 with the following applied loading axial load

ranging from 178-2600N, anterior-posterior load of 0.6 to 230N, and internal

external torque of 0-6Nm. The simulation was conducted at 1Hz during 75177
simulated gait cycles.
The tibial insert is then photographed, set up in a special and proposed system. The
fatigue crack damaged area is located by measuring the decreased light
transmission in the images. The image is then studied for measuring the crack
damage size and the locate the damaged areas.
Fatigue Life estimation of Artificial Hip Joint model using Finite Element
Method
It is stated that major causes of failures of implants are due to fatigue wear and
fractures caused by daily activities involving repetitive and fluctuating loads. In this
research work carried by the author, a hip joint model was designed using ANSYS,
and is analyzed using the finite element method. The simulation was set to have the
mechanical properties of UHMWPE. The peak stresses set in this simulation are set
from a range of 5.31 to 11.89 MPa. These numbers are the stress range that occur
during normal human activities and are the main cause of degeneration.
Before the simulation is conducted using finite element software of ANSYS, the
boundary condition must be set. The design is a right hip of one leg, et up in a
standing position. This right hip is considered to support the whole body weight of
an individu, considering the weight of the patient is 70kg. All the nodes at the
bottom are set as fixed points. The hip is subjected to a vertical load of 1304N (fast
walking), 1270N (norma walking), 431.9N (knee bending) and 1473N (walking down
the stairs). A muscle frce f 1937 at an angle of 20 degrees is also considered.
The von misses stresses of each load are obtained from the static analysis. For
safety design, the von misses stress must be lower than the yield stress of the
prosthesis material. The results of the von misses stress shows that the maximum
stresses are concentrated on the neck portion of the hip joint. The displacement and
the stress distribution are obtained in each applied load.
Fatigue Analysis of the specimen is then observed. A cyclic fatigue loading machine
with a max of 100.095kN and strain range of 12.57 mm range is used to conduct
the test. The test is performed with a frequency of 20 Hz. The results are shown.
The plastic deformation and necking was not seen during the test. Fibrous fracture
face and shearing edges were found, indicating a propagation of crack and fracture
caused by the cyclic variation of load. Different regions on the surface experience
different stresses, which results in different fracture morphology within the
specimens.
Fatigue life of the hip joint model is also evaluated using the data analysis achieved
from the von misses distribution. After calculation, the estimated value of life is
obtained to be 0.3284 x 105 cycles.