Development of FRP composite structural biomaterials: fatigue strength of the fiber/matrix interfacial bond in simulated in vivo environments.

Fiber/matrix interfacial bonding in fiber reinforced polymer (FRP) composite materials is potentially sensitive to degradation in aqueous environments. Ultimate bond strength (UBS) in carbon fiber/polysulfone (CF/PSF) and polyaramid/polysulfone (K49/PSF) was previously reported to be significantly decreased in two simulated in vivo environments. While UBS is a useful parameter, for orthopedic implant applications the fatigue behavior of the interface is probably a more relevant indicator of long-term composite material performance. In this article, the effects of simulated in vivo environments (saline, exudate) upon the fatigue behavior of the interface of CF/PSF and K49/PSF are reported. The fatigue behavior of both material combinations was linearly dependent on the logarithm of fatigue life in the dry (control), saline, and exudate environments. Testing either material in saline and exudate resulted in significantly lower fatigue strength than in the dry environment; however, results in the two wet environments were indistinguishable. The CF/PSF interface experienced fatigue failure at approximately 10(5) load cycles at a maximum applied load level of only 15% of its ultimate dry bond strength without indication of an endurance limit being reached. These results raise some important questions regarding the durability of CF/PSF composite in load bearing orthopedic applications.