A study of the fatigue properties of small diameter wires used in intramuscular electrodes.

Single and multi-strand stainless steel and cobalt-nickel alloy wires, with strand diameters from 26 to 46 microns, were fatigue tested using a modified rotating bending test to determine what factors are most important in controlling fatigue life. The relation between cyclic strain and cyclic life was determined for each material by cyclically straining test specimens at various strain ranges and recording the number of cycles to failure. The results show that (a) the fatigue curves of the 316LVM, MP35N, DBS, and Syntacoben wires are very similar and have many of the same fatigue characteristics of specimens of large cross section. (b) Multi-stranded wires have the same average fatigue life as their individual constituent strands, but the variance of that life is smaller. (c) Deformities in the wire, which are created during the manufacturing, appear to have the effect of shortening the fatigue life of these small section wires. (d) Observation of wire fracture surfaces show a relatively small crack propagation zone and a large fast fracture zone suggesting that most of the fatigue life of these small wires is in the original crack formation, which creates a large stress concentration and quickly leads to wire failure. (e) The size of the wire cross sectional area is of secondary importance compared to the amplitude of the maximum cyclic strain of the individual strands in determining fatigue life of the cable. To maximize the fatigue life of electrodes in vivo, the highest fatigue life for a given bending radius of curvature is desired. This suggests wire strands should be manufactured at the smallest diameter possible (without introducing structural flaws) to maximize service life.