Quantitative analysis of the effect of porosity on the fatigue strength of bone cement

This paper reports on the effects of porosity and its distribution on the fatigue strength of bone cement. Hand-mixed (HM) and vacuum-mixed (VM) bone cement samples were fatigue tested to failure. The point of failure commonly coincided with large single pores (in the VM materials) and multiple pores in clusters (in the HM material). The effect of pores was analysed using the Theory of Critical Distances (TCD), a theory previously developed to explain the effect of notches and other stress concentrations on fatigue and fracture. Clusters of pores were analysed by developing a criterion to decide whether local cracking would act to link pores together, forming a single stress concentration of more complex shape. This approach enabled us to predict the high-cycle fatigue strength of samples containing clusters of pores, with good accuracy (errors less than 13%). We then used the analysis to develop general rules for the effect of pore size and proximity on fatigue strength. For example, we showed that a single pore of 2 mm diameter or more would cause a significant decrease in the fatigue strength (compared to that of pore-free material); however, two pores of only 1 mm diameter in close proximity would be equally damaging. This demonstrates the importance not only of pore size but also of pore density and distribution. However, pores do have beneficial effects such as improved drug dispersion, bone ingrowth and crack tip blunting. Therefore, given the findings from this study, a possible step forward in the development of surgical bone cements may involve a compromise in which relatively small pores are evenly distributed throughout the material.