Be Careful Walking the Dog: An Orthopedic Leg Brace Failure

A woman was fitted with and wore an orthopedic leg brace. In less than a year, while walking her dog one evening, the brace failed suddenly resulting in a break in her femur.

The leg brace consisted of two wrought aluminum uprights each with an articulating joint at knee level. One of the uprights had failed causing the woman’s fall and injury. A fractographic examination revealed brittle fracture initiated by stress corrosion cracking. The investigation turned to identifying the offending corrosive agents and whether the brace had been fitted properly.