Andy Mercier can’t really identify the cause-effect relationship that led to his hip deteriorating. Mercier, Portland (Oregon) District Manager for Smith & Nephew Orthopaedics, first noticed symptoms while training for his first marathon when he was 43. “I’ve led a very active lifestyle with long distance bicycling (two cross country cycle camping tours), cross country and downhill skiing,” he says. “I thought those first symptoms were signs of a ligament injury or a muscle pull that I was treating improperly. Needless to say, I was a bit stunned, then depressed when I received the diagnosis.” Mercier’s doctor diagnosed a degenerating hip.

“Over the next five years I adapted as best I could to remain active with increasingly limited joint motion and pain,” he says. “Putting on a sock and tying my shoe became a daily chore to dread.”

“I finally was unable to complete a century ride in the fall of ’03 and subsequently experienced excruciating, disabling pain while hiking.” He realized the time had come to consider alternatives, including a hip replacement.

“In the period between diagnosis and decision I had plenty of time to investigate, and my job gave me access to all the information about new technologies and techniques. There were a couple of competing products that had very attractive features,” he says.

From the start, Smith & Nephew’s Oxinium™ replacement had a “leg up” on the competition and not just for the obvious reasons. Mercier already had access to in-depth information, including detailed case histories, about his company’s relatively new oxidized zirconium-niobium alloy implant.

It was February 2001 when Smith & Nephew first introduced its biocompatible zirconium alloy knee replacements to the world of orthopaedics. Since then, thousands of patients had opted for the company’s Oxinium knee. Their reasons were compelling.

According to www.oxinium.com, oxidized zirconium addresses the critical issue of debris produced by implants as a result of friction between articulating surfaces of an implant. The alloy’s strength is another benefit. Gordon Hunter, the Smith & Nephew Senior Research Project Manager who helped develop the knee replacement, points out that the alloy has supported 1000 lbs. over ten million cycles in knee testing.

The line extension into hip replacements was as smooth as Oxinium’s shiny black oxide surface. In 2003, Smith & Nephew announced “the introduction for the first entirely new bearing surface for artificial hip joints in more than 20 years.” According to the company, the new technology addresses two primary concerns surgeons have about hip implant: wear and fracture, both of which can lead to premature implant failure and additional surgery. “Oxinium implants provide patients with the toughness of metal implants, but the wear reduction of ceramic, yet has been shown to have none of the risks commonly associated with either material,” according to Smith & Nephew.

The company’s web site describes a typical hip replacement procedure, in which surgeons remove the top portion of the femur, replacing it with a metal stem with a ball on one end. In addition, the surgeon prepares the acetabulum, or hip socket in the pelvis, replacing it with a metal shell and plastic liner. Over time, as the new ball rotates against the plastic liner, the liner can wear down, requiring follow-up surgery (usually 10 to 15 years later) to repair the implant. Smith & Nephew points out that in contrast, Oxinium hip implants can reduce implant wear by nearly 50 percent.

In the past, surgeons have successfully reduced the wear factor by implanting a hard, low-friction ceramic ball rather than a tough metal ball. Although ceramics can extend the life of hip implants by reducing this wear, some ceramic implants may be prone to fracture inside patients, according to Smith & Nephew.

These and other factors weighed heavily in Mercier’s decision. “The tiny particles generated by wear of an artificial joint can produce an immune system response to the ‘foreign bodies’ if they accumulate beyond the individual’s tolerance,” he says. “I was also attracted by the absence of any catastrophic failure modes. With my desire to return to aggressive skiing, I was somewhat concerned with that issue.”

“In the final analysis, I felt that an Oxinium surface, articulating with the best polyethylene available, was the safest solution for someone who wanted to resume a very active lifestyle,” he says. He decided to move forward with the surgery. Mercier wasn’t alone. Each year, approximately 340,000 total hip replacement surgeries are performed in the United States, and 600,000 globally.

After his procedure at the University of California, San Francisco, Mercier took baby steps down the road to recovery. “I was weak as a kitten,” he recalls. “In the following weeks I regained my mobility and freedom incrementally. About five and a half weeks out, I snuck out on my bicycle while my wife was out shopping,” he says.

Today, the hip implant that started as raw zirconium at Wah Chang’s Albany, Oregon mill has drastically changed Mercier’s life. “Just tying my shoes without pain is a tremendous daily benefit that I’m starting to take for granted,” he says. “My real joy has been a return to very active cycling. This past year I’ve logged 5,000 miles, including rides of up to 175 miles in a day. I did go downhill skiing one day last winter, but with much trepidation. This year I’m looking forward to an active ski season as well. I just can’t say how much of a difference it’s made to get back the function in my hip. It’s really transformed my lifestyle. Like all people who have a joint replaced, I’d have done it a year earlier if I’d known then what I know now.”

As for the future of his product line, Mercier says that Smith & Nephew always has an eye out for other medical applications involving oxidized zirconium. “People are always asking about Oxinium-on-Oxinium articulations,” he says. “This may be investigated in the future, but it presents some significant engineering challenges. In addition, “It’s a relatively new material and many surgeons remain skeptical.”

“Right now the company is developing a revision total knee implant system. Later, the company can take the technology to shoulder implants and hip fracture treatment implants. We could potentially put this material in most any product with an articulating couple;” however, he continues, “mostly we need to address a larger portion of the total knee and total hip patient population.
Mercier is leading by example. He seems to relish being a walking testimonial for his own product line. “I haven’t been shy about sharing my experience, before or after, with my customers,” he says, adding, “I certainly feel I can communicate in a more credible way with customers now that ‘I’m not just the President of the Club; I’m a member.’”

For more information about Smith & Nephew’s products, visit them online at www.smith-nephew.com. To learn about ATI Wah Chang’s zirconium and other metals that make a difference, visit www.wahchang.com.

Disclaimer: This article is not intended to be an endorsement by Wah Chang of the medical products or procedures described.

ATI’s Biomaterials and Metals for Medical Devices The Allegheny Technologies family of companies manufactures implantable metallic biomaterials in an assortment of semi-finished mill product forms for use in a variety of applications, including: •  Orthopaedics •  Reconstruction •  Trauma •  Sports medicine •  Spinal •  Cardiovascular •  Tools •  Instrumentation ATI’s metallic biomaterials include specialty steels, cobalt-base alloys, titanium and titanium alloys, NiTiNOL, zirconium alloys, as well as other specialty metals. In addition, ATI companies manufacture many non-implantable metallic materials with special properties for other medical applications, including stainless steels, cutting tools, tool steels, high speed steels, maraging steels, electrically conductive metals, magnet metals, and wear resistant metals. For more information, visit www.alleghenytechnologies.com.

For more than 40 years, Wah Chang’s laboratory personnel have produced high quality inorganic analytical test results using an array of equipment and methods. After all of this time, the extremely knowledgeable lab staff still consistently meets and exceeds customer expectations in a variety of industries, while maintaining client confidentiality. But, as good as the staff is, it is only as good as the tools at its disposal.

Enter the latest addition to Wah Chang’s long list of equipment capabilities — its new Scanning Electron Microscope (SEM). According to Gary Hanson, Senior Metallographer in Wah Chang’s Process Development Department, the new instrument functions similarly to its predecessors, with the exception that “it does everything much better.”

“Everything” includes taking photographs of materials, primarily metals, for extremely accurate analysis. The images produced by the new machine have a higher resolution, are produced faster, and are more accurate. More depth of focus in the enhanced images yields literally miniscule detail on fracture analysis. Analysis of these images offers answers to in-service performance and gives detail on material that comes out of Wah Chang’s own facility, helping to ensure product quality.

In addition to the complete offering of tests that the Analytical Laboratory already provides, the new SEM looks at sample sizes from microscopic to 3/4 inch thick at magnifications ranging from 10x to 300,000x. By using the energy-dispersive x-ray microanalysis system, the lab performs qualitative and quantitative analysis for the study of different structural characteristics. Examples include analysis of metal fractures, particle size and size distribution, physical microstructure observation and image analysis. Although most analyses are performed on metals, glass and other materials have been analyzed.

The most welcomed feature on the new instrument, according to Hanson, is its ability to monitor its beam current. “The more we can standardize samples to pure element standards, the more accurate the quantitative analysis is,” he explains. “We can do that now with the new instrument’s beam current monitor.”

With the new SEM, materials being analyzed can be viewed in X-ray map, line scan, backscattered and secondary electron modes, among others, which quickly provides details on composition and structure. This capability allows our labs to provide customers with a clearer picture of their metal’s analysis and confidence in product quality.

Wah Chang’s additional Analytical Laboratory capabilities include Interstitial Gas Analysis, Plasma Emission Spectroscopy, Inductively-Coupled Plasma-Mass Spectroscopy (ICP-MS), Atomic Absorption Spectroscopy, Gamma Ray Spectroscopy, Particle Size Analysis, X-Ray Diffraction and Water Analysis. The company’s full array of services is rounded out by its Corrosion Lab, Metallurgical Lab, Radio Analytical Lab, and Corrosion Solutions® Conference and Seminars. For more information, visit www.wahchang.com.

QUESTION:

Wah Chang continues to receive questions concerning potential processes for the welding of dissimilar reactive and refractory metals.

ANSWER:

As previous articles pointed out, zirconium can be welded to other reactive and refractory metals, such as titanium, niobium, tantalum, hafnium and vanadium. Zirconium, however, cannot be fusion welded to other materials of construction such as copper, iron or nickel.



Although it is possible using the fusion welding technique to join reactive and refractory metals, the results can cause dramatic deterioration in both corrosion resistance and in mechanical properties. For example, a zirconium-to-titanium fusion weld would have much lower corrosion resistance in corrosive media than pure metals, depending on the media it is exposed to. The corrosion resistance may be acceptable in portions of the weld that have compositions near that of the parent metals, but it would show localized areas (e.g. 50Zr/50Ti composition) that exhibit extremely high corrosion rates.

With regards to the mechanical properties, the final weld will be affected by solid solution hardening resulting in a weld with very poor ductility and very high hardness. In the case of a zirconium-to-titanium fusion weld, localized areas will have a hardness almost double that of the parent metal. In addition, if a dissimilar metal weld (Zr to Ti) is heat treated at temperatures as low as 625°C, the weld can deteriorate rapidly due to unequal oxidation rates of the Zr to Ti weld. (See Outlook issue Volume 24, No. 3 for more information).

The bottom line is that, although reactive and refractory metals can be fusion welded together, the resulting weldment may exhibit very poor properties; so it should be discouraged when used in any structural or corrosive application.

For more information, contact Wah Chang at 541-967-6955.

Ron Graham has been promoted to Vice President of Quality and Technology at ATI Wah Chang.

“Ron’s promotion to Vice President acknowledges the importance of quality and technology in our products,” said Lynn Davis, ATI Wah Chang President. “Both play a big role in our sales these days.”

Mr. Graham has published and presented papers on metals topics around the world and is considered an expert in his field, according to Mr. Davis. “Ron has a strong background in nuclear-related materials, one of our key businesses and has worked with the management of quality systems during most of his career,” he said.

Mr. Graham’s experience is broad, including 30 years in program/project management and development of advance products for nuclear energy, aerospace, medical and chemical process industry applications.

Since joining Wah Chang in 1985, Mr. Graham has worked in a variety of positions including, Principal Research Metallurgist, Manager Process Engineering, as well as Director of Metallurgical Operations, Materials Engineering, Technology, and most recently, Quality and Technology.

Mr. Graham received his BS in 1971 from University of Missouri-Rolla in Metallurgical Engineering and his MS in 1973 from University of Florida in Materials Science. Prior to joining Wah Chang, he was a program manager for fast breeder reactor fuel fabrication at the Department of Energy at Hanford, Washington.

You can reach Mr. Graham by email at ron.graham@wahchang.com.

Dennis Hamm joined Wah Chang’s titanium sales team in December 2004 and has been assigned sales responsibilities for the Wah Chang Ti Wire Facility in Frackville, Pennsylvania.

Prior to joining Wah Chang, Mr. Hamm worked in sales for Scottsboro Aluminum, based in Scottsboro, Alabama. In previous positions, he was a product manager for welded tube products and also sold painted coil and sheet products.

“After leaving Scottsboro Aluminum I was looking for an opportunity to work with a company that had a strong foundation and large opportunity for growth,” said Mr. Hamm, “and Wah Chang has both.”

You can reach him by email at dennis.hamm@wahchang.com or by phone at 256-722-2307.

The 2005 Corrosion Solutions Conference is several months away and the technical sessions are nearly filled. Sessions for the September 12-15 technical portion of the conference include Corrosion Challenges, which features case histories and other valuable information; Material Developments, with discussions of ATI®425 and other alloy developments; Fabrication Advances, in which some of the world’s best fabricators share ideas and discuss a variety of issues; as well as topics focused on specific media, such as acetic, nitric, and other acids.



Keynote speakers include Materials Engineer Gene Liening of Dow Chemical; Joseph Chang, Editor of Chemical Market Reporter; Dr. Jack Shilling, Vice President of Technology for ATI; and Dr. Michael Renner, Technical Director at Bayer. Presentations include topics ranging from Materials of Construction for Urea Plants by Derrill Holmes of Wah Chang to Process Chemistry Determines Metallurgy by Gordon Lentz of Millennium.

If you are still interested in presenting a paper, contact us as soon as possible (e-mail Mr. Rick Sutherlin at rick.sutherlin@wahchang.com). There are very few opportunities left to take advantage of this unique forum. Note that not all abstracts are accepted.

In all, we expect over 40 technical presentations at the 2005 event, including a few timely panel sessions. Below are just a few samples of the abstracts we’ve received thus far. Please review them, and visit our web site at corrosionconference.com for the latest updates and online registration. Contact Customer Service at 541-967-6977 for additional information regarding this unique event.

Corrosion Solutions® Seminar
May 3-4, 2005 — Albany, Oregon
Wah Chang is accepting registrations for its 2005 Corrosion Solutions Seminar to be held May 3-4, 2005 in Albany, Oregon. The seminar is designed to help participants make technically and economically sound decisions when selecting and working with specialty materials for corrosive applications.

The class, presented by professionals in materials engineering, metallurgy and other technical disciplines, will benefit a wide range of participants, including, but not limited to, chemical, design, materials and other engineers, as well as fabricators and maintenance personnel.

The fee for the seminar is $495. Lunches are provided and further details about accommodations will be included in an information packet. For more information, call Sheryl Renzoni at 541-926-4211 x6280, or visit www.wahchang.com.



ISOHIM 2005
June 13-17, 2005 — Uppsala, Sweden
Wah Chang is pleased to announce that it will be a sponsor of the 2nd International Symposium on Hydrogen in Matter. The event will be held in June 13-17, 2005 at the Ångström Laboratory at Uppsala University.

Topics will include dynamics and thermodynamics of hydrogen in metals, semiconductors and oxides; hydrogen surface and interface interactions; biological aspects; alloy and powder production; nuclear reactors; and hydrogen storage and purification.

For more information about this event, visit www.akademikonferens.uu.se/ISOHIM or e-mail ISOHIM@akademikonferens.uu.se. (Note that this symposium will not have an exhibit hall.)



Reactive Metals Welding Seminar
July 19-21, 2005 — Albany, Oregon
In response to an increasing number of requests, Wah Chang will again offer its Reactive Metals Welding Seminar. The 23rd annual seminar will be held July 19-21, 2005 in Albany, Oregon. A second seminar may be held August 2-4, 2005 if the first class cannot accommodate the number of interested participants.

The weld training courses will consist of classroom lectures and hands on welding of typical zirconium, titanium and TiNb weldments. Wah Chang asks that only experienced welders enroll and that they have knowledge of gas tungsten arc welding of stainless steel or aluminum. Space is limited, so we will be admitting participants on a first-come, first-served basis.

The charge for this Reactive Metals Welding Seminar is $299 and includes lunches. A list of accommodations is available upon request. For more information, contact Sheryl Renzoni at 541-926-4211 x6280.

ATI Wah Chang is pleased to announce the launch of corrosionconference.com, a web site focusing on the company’s Corrosion Solutions® Conference. The site enables visitors to quickly learn about the 5th biennial corrosion-related event, review conference dates and schedules, and even register as either an exhibitor or an attendee. In addition, corrosionconference.com contains a sampling of abstracts covering just a few of the more than 30 topics that will be addressed.



For those who haven’t been to Sunriver, Oregon and experienced its beauty firsthand, the web site contains a few tempting pictures and details about the resort and its many natural attractions.

Please visit www.corrosionconference.com and send me any feedback you would like to share. We at Wah Chang are committed to providing you with helpful information regarding our signature events and are always looking for ways to improve. You can reach me at kirk.richardson@wahchang.com. I hope that you’ll choose to join us in Oregon’s high desert this fall.

.

LYNN DAVIS
President

PARRY WALBORN
Vice President — Commercial

ANDY NICHOLS
Director of Marketing

GARY KNEISEL
Director of Sales

KIRK RICHARDSON
Editor

BETH GILLETTE
Assistant Editor

Copyright ©2005 Wah Chang. All rights reserved. Reproduction of this newsletter by any means, in whole or in part, without written permission is prohibited by law. Outlook is published quarterly by Wah Chang. The newsletter contains information on reactive and refractory metals, including hafnium, niobium, titanium, vanadium and zirconium, as well as chemicals. The properties listed herein are average values based on laboratory and field test data from a number of sources. They are indicative only of the results obtained in such tests and should not be considered as guaranteed maximums or minimums. The starburst logo and Wah Chang are registered trademarks of ATI Properties, Inc.

ATI Wah Chang
(headquarters)
P.O. Box 460
Albany, Oregon 97321
T 541.926.4211
F 541.967.6990
www.wahchang.com
www.corrosionsolutions.com
www.wahchanglabs.com

Sales/Tech Support
T 541.967.6977
F 541.967.6994
custserv@wahchang.com

CPI Service Center — US
T 541.917.6739
F 541.924.6882
ellen.baumgartner@wahchang.com

CPI Products
T 541.967.6906

Nuclear-Grade Alloys
T 541.967.6914

Ti, V, and Nb Products
T 541.967.6977

ATI Allvac
PO Box 5030
Monroe North, Carolina 28111-5030
T 704.289.4511
www.allvac.com

ATI Allegheny Ludlum
500 Six PPG Place
Pittsburgh, Pennsylvania 15222
T 800.258.3586
www.alleghenyludlum.com