Zirconia femoral head fractures: a clinical and retrieval analysis.

Zirconia femoral heads provide increased fracture strength, but 343 zirconia head failures have been documented since 2000. Retrieval analysis of 6 fractured heads, 4 suspect heads, 4 control zirconia heads, and 2 failed alumina heads was performed. Zirconia failures have been isolated to heads sintered in a "tunnel" furnace introduced in 1998. The monoclinic composition at the taper surface of fractured and nonfractured heads was significantly elevated (21% to 68%) compared to that of control zirconia heads (less than 5%). Electron microscopy identified circular fracture footprints unique to the zirconia heads produced in the tunnel furnace. Cobalt chrome heads were used in the urgent revision setting due to Morse taper damage. Partial capsulectomy was performed in an effort to reduce future third body wear. Monoclinic phase transformation following implantation remains a potential mechanism of ceramic head failure. We recommend that patients with recalled zirconia heads be advised of a potential fracture risk.