High wear resistance of metallocene polyethylene with long-chain branch for artificial joints

Ultra-low-wear polyethylene (ULWPE) is a promising material for artificial joint implants, owing to its good biocompatibility and wear resistance. However, its molecular weight is almost an order of magnitude lower than that of Ultrahigh molecular weight polyethylene (UHMWPE). The mechanism between wear resistance and the structure of ULWPE is still unknown. This study analyzed their attributes from microstructure to macroscopic performance and revealed the wear resistance mechanisms of ULWPE by conducting an in-depth investigation of four types of polyethylene, including ULWPE, UHMWPE, and high-density polyethylene. Impact tests showed that ULWPE, with a molecular weight of 282 kg/mol, exhibited an impact energy of 110 kJ/m2, surpassing the 97 kJ/m2 recorded for UHMWPE (molecular weight over 5000 kg/mol). Furthermore, tribology tests indicated that the wear rate of the most anti-wear ULWPE was 4.479 ± 0.040 mm³/Mc, which was significantly lower than the 5.601 ± 0.456 mm³/Mc for UHMWPE. The excellent mechanical properties and wear resistance of ULWPE were derived from its unique structure. Dynamic rheological assessments and thermal classification techniques confirmed that ULWPE had long-branched chains. The long-branched chains markedly increased the proportion of the high entanglement and the tie molecules in the amorphous regions, endowing it with superior toughness. At the same time, the high crystallinity of ULWPE gives it sufficient hardness and strength. The combination of high crystallinity and high entanglement endowed ULWPE with a good balance between strength and toughness, leading to its exceptional mechanical properties and wear resistance. This study provided robust data for ULWPE's clinical use and theoretical insights for designing durable, implantable polymers.