Failure analysis of a fractured stainless steel femoral bone plate

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-02-26 DOI:10.1016/j.engfailanal.2025.109466

Luiza de Brito Fantin, Marcelo Ferreira Moreira, José Marcos Paz de Souza

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Abstract

This study investigated a femoral bone plate that fractured after 6 months of use in a patient who had already experienced a similar implant failure. Chemical analyses, Vickers hardness measurements, and metallographic and fractographic examinations showed that the compression plate was following the chemical and microstructural requirements set by the ISO 5832 standard, and no material or manufacturing defects could be associated with the premature failure of the plate. The fracture occurred on the seventh of the fourteen holes of the plate and the failure mode was identified as bending fatigue. The main fatigue cracks nucleated on the edge of the compression hole and propagated through the plate towards the bone. Finite elements analysis results confirmed that fatigue crack nucleation sites were regions of maximum stress concentration. Lack of bone healing was the most probable cause for the excessive loading of the plate, and the failure might have been prevented with better stabilization of the bone fracture region, although analyses of surgical and post-operative medical procedures were outside the scope of this investigation. Additionally, a brief discussion regarding orthopedic implant failures in Brazil was conducted. By analyzing 25 other failure cases, it was found that most of them are related to the device itself and might have been prevented through a better technical certification process and implant monitoring by the national health regulatory agency.

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.