Biomoteriols 18 (1997) 437439

0 1997 Elsevier Science Limited

Printed in Great Britain. All rights reserved
PI1 SO142-9612 (96) 00067-I 0142-9612/97/$17.00

Experimental study of mechanical

properties of composite carbon screws
S. Blaiewicz, J. Chlopek, A. Litak*, C. Wajler and E. Staszkbw+
University of Mining and Metallurgy, Cracow, Poland; *University of Technology, Cracow, Poland; +St. ieromski
Municipal Hospital, Cracow, Poland

Carbon+zarbon composite was used to manufacture carbon screws as possible material for
osteosynthesis. The mechanical properties were optimized including the fibre orientation in the
composite volume, the effect of the size of the thread and the thread shape. The mechanical properties
of the carbon screws were compared with conventional OSTEO steel cortical screws. Two types of
carbon specimens were used, varying in fibre orientation along the screw axis. The mechanical
properties of the carbon screws including the failure force for one thread and the critical shear stress
were determined. The force destroying the connection of the carbon screw with bone was determined.
The holding capacity of the carbon screw was compared to the steel screw. The extraction tests
demonstrated 50% less holding force than the OSTEO steel screw. 0 1997 Elsevier Science Limited.
All rights reserved

Keywords: Carbon-carbon composite screws, osteosynthesis, mechanical properties

Received 8 October 1995; accepted 5 April 1996

Although metal alloys are the most popular materials for
structural implants, their use in medicine creates many
problems. One of the major problems is their low
compatibility with bone tissue in terms of physical and
mechanical properties; for example, the modulus of
elasticity of Co-G-MO alloy is nearly 30 times that of
bone’. Stress shielding, the possible side-effects of
metal ion release, their considerably greater density in
comparison to bone and occasional allergic reactions
are also disadvantages of metals in medical applications.
This mismatch of the mechanical properties of metallic
implants with bone produces a stress distribution in the
femur different from one without the implant. The
growth of bone during osteosynthesis is a function of
stress, and the change in the stress distribution may
result in the development of a bone structure in the
zone near the implant different from the original
pattern. The difference in elasticity of a metallic
implant and bone may cause loosening of the implant’.
The advantages of using a composite material lie in the
possibility of optimizing both the material’s modulus
and strength3. Carbon-carbon composites have proved
to be acceptable in several situations4-6. Owing to their
unique physical and chemical properties they occupy
an outstanding position in the composite family,
enabling barriers to be overcome in various fields of
technique and medicine. By using various types of
carbon matrix precursor, reinforcing carbon fibres,
various geometries of composites and thermal treatment
conditions, their properties can be altered718. This paper
discusses carbon screws for osteosynthesis, with
experimental investigation taking into account the size
and shape of the thread. The strength of a carbon
screw-cortical bone joint was determined.
Correspondence to Dr S. Blaiewicz.
EXPERIMENTAL
In the first experiment a carbon screw was modelled like
the cortical OSTEO screws. The geometrical parameters
of the screws investigated were: thread diameter,
4.5 mm; core diameter, 3.0 mm; length, 45 mm.
Carbon screws were obtained by mechanical
treatment of carbon bars made of carbon-carbon
composite, by a method of manufacturing described
elsewhere’. To obtain the carbon screws, two ways of
arrangement of the carbon fibres in the carbon matrix
were applied. The schemes of preparation of the
carbon bars are shown in Figure 2. In the first type
(Type 1) the carbon fibres were laid parallel to the bar
axis, and during further mechanical treatment the
system of fibres remained parallel to the screw axis. In
the second case (Type 2) the core of the bar contained
a parallel system of fibres, whereas the external layers
were formed in the shape according to the cutting
direction of the thread.
These carbon screws obtained by the two different
methods were tested on a Zwick 1435 testing machine.
The screws were screwed in the tapped holes made in
two separated polyacetate plates. Subsequently, the
plates with the screw mounted in machine grips were
stretched with a constant speed of 1 mm min-‘.
Type1 Type2
Figure 1 Schematic representation of carbon matrix
preparation.

437 Biomaterials 1997, Vol. 18 No. 5

438 Mechanical properties of composite carbon screws: S. Biaiewicz et al.

Table 1 Mechanical properties of composite carbon screws 26

Type 1 Type 2 n
m 24
Failure force on the length of 6 mm (N) 343 f 20 120f9 !k
Number of thread coils 3.4 3.4 m’
_. 22
Shearing surface (mm*) 38 38
t
Failure force for one coil (N) 280 AZ17 98i 12 $ 20
Critical shear stress (MPa) 25.3 12.5
kQ) 18
5
The holding force, the failure force for one turn of the 16
thread and the critical stress shearing the thread were
determined in extraction tests, and the results are 14 w
shown in Table 1. I I I I I I I
1.0 I.2 1.4 Li 1.8
The results presented in Table I show that the screws
Thickness of thread, mm
obtained from the unidirectional reinforced bar had
significantly better mechanical properties. The low Figure 3 Effect of the thickness of the thread crest on the
value of the critical shear stress for screw Type z shear stress of the carbon screw.
indicates a possible process of splitting up the layers
consisting of carbon fibres wound up under the 45” sheared thread coils. The main reason for this is the
angle with respect to the bar axis. The reason for the lowering of the critical shearing stress for one thread
delamination seems to lie in the difference in shrinkage coil resulting from an increase in the thickness of the
during the carbonization process with two kinds of thread profile.
layers building the bar. The screws made of composite The carrying capacity of the composite screw also
Type 1 were then subject to further modification. depends on the thread profile. As a result of further
modifications of the slope angle of the thread profile
from 30” (OSTEO profile) to 45”, an increase of about
MECHANICAL PROPERTIES OF THE CARBON 50% in the holding capacity of the screw was
SCREW THREAD obtained. Thus, by modification of the contour of the
carbon thread and its profile, the holding force was
The shape of the thread was modified in order to enhanced to 55ON. This indicates an improvement
improve the holding force and shear strength of the of about 50% in comparison to the initial OSTEO-
screw. A typical relation between the tensile force and type profile.
strain in the extraction test is shown in Figure 2.
The failure behaviour under loading of the carbon
screw is characterized by shearing of the single threads MECHANICAL PROPERTIES OF THE SCREW
one by one, resulting in destruction of the screw. The HEAD
result of modification of the screw shape is shown in
the relation between the critical shear strength and the The strength of the screw head was tested by an
thickness of the thread crest (width of base of thread estimation of the shearing force in the extraction test of
crest) (see Figure 3). the screw from the polyacetate plate. The influence of
Figure 3 shows that the critical shear strength of the the slope of head flange (x) and the distance between
carbon thread decreases with increasing thread pitch. the ending of the thread coil and the head (parameter
It may be assumed that the cause of this effect is due x) were examined. The influence of the first factor is
to the size effect in the brittle carbon thread. Thus, shown in Figure 4.
care must be taken to ensure the proper relation
between the thickness of the thread crest and the
650
holding force of the carbon screw. Increasing the
pitch of the carbon screw did not lead to an
600
improvement in the holding capacity of the screw, in
spite of an increase in the entire surface of the holding force
550 ____-_--

z_ 500
2 ---- T/
2 450

)
P
‘C 400
(II
g 350

300

r I I I lip T I
I I I I I I I I
.iU JS 4u 45 0 55
Strain Slope of head flange, degree

Figure 2 Tensile force-strain diagram of the carbon screw Figure 4 Effect of the slope of the head flange on the
in the extraction test. shearing force of the carbon head.

Biomaterials 1997, Vol. 18 No. 5

Mechanical properties of composite carbon screws: S. Blaiewicz et al. 439

Table 2 Comparison of failure force and shear stress of bone SUMMARY

thread for carbon and steel screws

Carbon screw/ Steel screw/ As a result of the study on tailoring the thread of screws
cot?. bone cork bone made of carbon composite, their holding capacity was
increased by about 50% in comparison to the
Number of thread coils 4 4 conventional OSTEO-type profile. Similarly, the holding
Failure force (N) 395 & 18 762 k 23 capacity of the carbon screw in bone tissue is greater by
Shear stress of bone 4.56 9.63
about 30% in comparison to the OSTEO-type profile.
thread (MPa)
This holding capacity represents 50% in comparison to
the union performed by using the OSTEO steel screw.
The critical value limiting the use of carbon screws is
As shown in this figure, in order to exceed the value the resistance to shearing of the thread, the
of the holding force for the screw examined (550N), improvement of which can be achieved by new
the angle M has to be greater than 50”. An increase in technological solutions.
the x parameter increases the resistance to shearing One possible solution is oxidative surface treatment of
the head, which may be explained by a lowering of the carbon screw resulting in the opening of the closed
the influence of the stress concentration resulting pores, since porosity of carbon screws is one of the main
from the thread. On the other hand, a decrease in the influences on their mechanical properties. A further
thread length decreases the active screw length and process of densification with carbon pyrolytically
the holding force of the screw. These investigations deposited from gaseous hydrocarbons in open pores
allowed us to obtain a value for the shearing forces of could improve the shear strength of the carbon composite.
the head greater than 550N, which means that the Moreover, the thin external pyrocarbon layer on the screw
value exceeds the holding capacity of the carbon surface formed during pyrolysis can improve the wear
screw. properties of this implant.
The experimental tests on the screws made of
carbon-carbon composites indicate their application
INVESTIGATION OF THE CARBON SCREW- for osteosynthesis where a high holding power is not
CORTEX BONE TISSUE JOINT required.

As a criterion of the usable holding power of the

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Biomaterials 1997, Vol. 18 No. 5