Effects of porosity on the fatigue performance of polymethyl methacrylate bone cement: an analytical investigation.

Porosity has been shown to affect the fatigue life of bone cements, but, although vacuum mixing is widely used to reduce porosity in the clinical setting, results have been mixed and the effects of porosity are not well understood. The aim of this study was to investigate the effects of porosity using stress analysis and fracture mechanics techniques. The stress concentrations arising at voids in test specimens were found using analytical solutions and boundary element methods. The fatigue life of specimens containing voids of various sizes was predicted using fracture mechanics techniques. For spherical voids that do not occupy a significant proportion of the cross-section, the resulting stress concentration is independent of void size and too small to account for the observed crack initiation. Cracks must therefore initiate at additional stress raisers such as radiopacifier particles or additional voids. For large voids, the stress increases as the remaining cross-section of the specimen decreases, and this may account for much of the observed reduction in fatigue strength in hand-mixed cement. Although crack initiation may be largely independent of void size, there is an effect on crack growth rate. Cracks are predicted to grow faster around larger voids, since they remain in the stress concentration around the void for longer. This effect may account for the relationship between porosity and fatigue life that has been observed in samples without large voids. Since porosity appears to affect crack growth more than initiation, it may be less damaging in high-cycle clinical fatigue, which may be predominantly initiation controlled, than in short laboratory tests.