Influence of residual thermal stresses on the edge chipping resistance of PFM and veneered zirconia structures: Experimental and FEA study

Objective

Chipping fractures of the veneering porcelain are frequently reported for veneered all-ceramic crowns. In the present study, the edge chipping test is used to measure the toughness and the edge chipping resistance of veneered zirconia and porcelain-fused-to-metal (PFM). The aim is to describe an edge chipping method developed with the use of a universal testing machine and to verify the accuracy of this method to determine the influence of residual thermal stresses on the chipping fracture resistance of veneering porcelain. A finite element analysis (FEA) was used to study the residual stress profiles within the veneering porcelain.

Analysis of thermal distributions in veneered zirconia and metal restorations during firing

Objective

The present work evaluated the thermal behavior of porcelain–metal and porcelain–zirconia restorations during fast and slow firing and cooling.

Methods

All-ceramic (porcelain on zirconia) and porcelain-fused-to-metal (PFM) molar crowns were fabricated with 1 or 2 mm porcelain thickness. Thermocouples were attached to the cementation (T1) and occlusal (T4) surfaces of the restoration and embedded at the framework–porcelain interface (T2) and inside the porcelain (T3) to acquire temperature readings by time. Slow heating was set as 45 °C/min and fast heating as 140 °C/min. For fast cooling, the furnace was opened immediately after the holding time. Slow cooling was effected by opening the furnace when it reached 50 °C below the T_g. Porcelains T_g were calculated for each cooling rate.

Results

Slow heating rate was measured at T4 as being 30 °C/min while fast heating at T4 was 100 °C/min. The measured cooling rates within the porcelain (T2) around the T_g range were 20 °C/min and 900 °C/min for slow and fast cooling, respectively. During slow cooling, similar temperatures were found for both zirconia and metal crowns. Remarkable temperature gradients were observed for the fast cooled all-ceramic crown (T1–T4 = 100 °C) and, of lower magnitude for PFM (T1–T4 = 30 °C). T_g of porcelains increase with faster cooling rates.

Significance

Slow cooling appears to be especially important for all-ceramic crowns to prevent high magnitude thermal gradients, which could influence cracking and fracture of the porcelain.     

Fracture resistance of porcelain veneered zirconia crowns with exposed lingual zirconia for anterior teeth after thermal cycling: An in vitro study

Statement of problem

In some clinical conditions minimally invasive complete crown tooth preparations are indicated. This is especially true when gross removal of tooth structure would weaken the remaining tooth or violate the vitality of the dental pulp.

Objective

The purpose of this study was to investigate the influence of (1) exposed lingual zirconia with veneered zirconia crowns, and (2) reduced lingual thickness of monolithic lithium disilicate crowns on the fracture resistance of the crowns after cyclic loading. Metal-ceramic crowns with exposed lingual metal served as controls.

Materials and methods

Twenty-four maxillary central incisor crowns were fabricated in identical shape on metal testing dies in 3 groups: metal-ceramic crowns (MC, n = 8), veneered zirconia crowns (VZ, n = 8), and monolithic lithium disilicate crowns (MO, n = 8). A conservative preparation design with 0.75 mm lingual clearance was used for each crown system. All crowns were cemented to their corresponding crown preparations with self-adhesive resin cement (Multilink Automix). The crowns were subjected to 1000 cycles of thermal cycling, then cyclic loading of 111 N by means of a stainless steel ball, and 50,000 cycles of loading were applied for the fatigue test. Fatigue loading was followed by a continuously increasing compressive load, at a crosshead speed of 1 mm/min until failure. The compressive load (N) required to cause failure was recorded. Means were calculated and analyzed with one-way ANOVA and the Tukey HSD test (α = .05).

Results

There was a significant difference between MO vs. MC (P = .0001), MO vs. VZ (P = .0001), and VZ vs. MC (P = .012).

Conclusions

There was a significant difference in the mean fracture resistance of MC, VZ, and MO crowns in this in vitro study. The MC group recorded the highest mean fracture strength.     

Influence of thermal expansion mismatch and fatigue loading on phase changes in porcelain veneered Y-TZP zirconia discs

There is a rapidly growing interest for the use of Y-TZP zirconia as core material in veneered all-ceramic prostheses. It was hypothesized that a mismatch in coefficient of thermal expansion between the veneering porcelain and the Y-TZP zirconia core of these prostheses causes transformation of the tetragonal to the monoclinic structure in Y-TZP zirconia at the interface boundary when exposed to fatigue loading, resulting in fracture at the interface boundary. Y-TZP zirconia discs were veneered with three porcelains differing in coefficient of thermal expansion. Finite element analysis was used to investigate the stress distribution in the bi-layered discs because of the mismatch in thermal expansion. Two of these three groups were fatigued with the veneering ceramic in tension. X-ray diffraction was used to measure the intensity of monoclinic and tetragonal zirconia phase present at the zirconia core surface after sintering, airborne abrasion, veneering, and fatigue loading. It was found that the sintered tetragonal structure was converted to monoclinic up to a depth of 27 mum after airborne abrasion, and reversed back to tetragonal after porcelain veneering with porcelain. Fatigue loading of veneered discs did not, even with the highest possible thermal mismatch stress, cause any conversion from tetragonal to monoclinic phase.     

Fracture stability of anterior zirconia crowns with different core designs and veneered using the layering or the press-over technique

In the current in vitro study, the fracture stability of anterior crowns with zirconia cores of different designs was investigated after applying different veneering techniques. Four groups of zirconia cores (n = 10 in each group) were produced using a computer-aided design/computer-aided manufacturing (CAD/CAM) process. Cores with a standard cervical design were veneered using the layering technique (CCL) or the press-over technique (CCP). Further cores were designed with a porcelain shoulder, where the cervical margin of the zirconia core was reduced by 1 mm. These cores were also veneered using the layering technique (PSL) or the press-over technique (PSP). All crowns were cemented onto metal teeth and loaded until fracture in a universal testing machine. Chipping or fracture of the core was found to occur for CCL at 919±265 N (mean ±SD), for CCP at 798±226 N, for PSL at 739±184 N, and for PSP at 734±209 N. anova did not show significant differences between the four groups. For CCL and CCP, fracture lines ran in a mesio-distal orientation. For PSL and PSP, fracture lines ran into the porcelain shoulder. In summary, the use of a porcelain shoulder can be recommended with zirconia crowns in combination with either the layering or the press-over veneering technique.     

In vitro evaluation of fracture strength of zirconia restoration veneered with various ceramic materials

PURPOSE

Fracture of the veneering material of zirconia restorations frequently occurs in clinical situations. The purpose of this in vitro study was to compare the fracture strengths of zirconia crowns veneered with various ceramic materials by various techniques.

MATERIALS AND METHODS

A 1.2 mm, 360° chamfer preparation and occlusal reduction of 2 mm were performed on a first mandibular molar, and 45 model dies were fabricated in a titanium alloy by CAD/CAM system. Forty-five zirconia copings were fabricated and divided into three groups. In the first group (LT) zirconia copings were veneered with feldspathic porcelain by the layering technique. In the second group (HT) the glass ceramic was heat-pressed on the zirconia coping, and for the third group (ST) a CAD/CAM-fabricated high-strength anatomically shaped veneering cap was sintered onto the zirconia coping. All crowns were cemented onto their titanium dies with Rely X™ Unicem (3M ESPE) and loaded with a universal testing machine (Instron 5583) until failure. The mean fracture values were compared by an one-way ANOVA and a multiple comparison post-hoc test (α=0.05). Scanning electron microscope was used to investigate the fractured interface.

RESULTS

Mean fracture load and standard deviation was 4263.8±1110.8 N for Group LT, 5070.8±1016.4 for Group HT and 6242.0±1759.5 N for Group ST. The values of Group ST were significantly higher than those of the other groups.

CONCLUSION

Zirconia crowns veneered with CAD/CAM generated glass ceramics by the sintering technique are superior to those veneered with feldspathic porcelain by the layering technique or veneered with glass ceramics by the heat-pressing technique in terms of fracture strength.     

Microstructure of veneered zirconia after surface treatments: A TEM study

Objective

Clinical studies reveal that veneer chipping is one major problem associated with zirconia based dental restorations, the underlying mechanisms being still investigated. We semi-quantitatively analyzed the effects of different surface treatments (thermal etching, 35/105 μm sandblasting and coarse bur drilling (150 μm)) on the microstructure of a zirconia veneered dental ceramic.

Methods

The relative monoclinic content on zirconia surfaces was determined using X-ray diffraction (XRD). The microstructure at the zirconia–veneer interface has thereafter been investigated using transmission electron microscopy (TEM). Selected area electron diffraction (SAED) was used to qualitatively assess the depth of the stress-induced phase transformation.

Results

Sandblasting or bur drilling significantly roughened the zirconia surface. A reverse transformation of already transformed monoclinic zirconia grains back into the tetragonal polymorph has been observed after thermal veneering treatment. In TEM, the mechanically treated samples revealed a highly damaged area of 1–3 μm from the interface. The presence of monoclinic phase in veneered zirconia samples has been observed in SAED up to depths of 4 μm (35 μm sandblasted), 11 μm (105 μm sandblasted) and 9 μm (150 μm diamond drilled) below the interface.

Significance

Regardless of the treatment protocol and produced roughness, the veneering ceramic perfectly sealed the zirconia surface. XRD showed an increased amount of monoclinic phase on the surface treated zirconia. However after thermal treatment, the monoclinic phase was re-transformed into the tetragonal polymorph. TEM/SAED analysis has found indication for a greater extend of the monoclinic transformation into the bulk zirconia compared to the treatment related defective zone depth.     

Residual stresses explaining clinical fractures of bilayer zirconia and lithium disilicate crowns: A VFEM study

ObjectiveTo understand the stress development in porcelain-veneered zirconia (PVZ) and porcelain-veneered lithium disilicate (PVLD) crowns with different veneer/core thickness ratios and cooling rates. To provide design guidelines for better performing bilayer restorations with the aid of Viscoelastic Finite Element Method (VFEM).MethodsThe VFEM was validated by comparing the predicted residual stresses with experimental measurements. Then, the model was used to predict transient and residual stresses in the two bilayer systems. Models with two different veneer/core thickness ratios were prepared (2:1 and 1:1) and two cooling protocols were simulated (Fast: ∼300 °C/min, Slow: ∼30 °C/min) using the heat transfer module, followed by stress analysis in ABAQUS. The physical properties of zirconia, lithium disilicate, and the porcelains used for the simulations were determined as a function of temperature.ResultsPVLD showed lower residual stresses than PVZ. The maximum tensile stresses in PVZ were observed in the cusp area, whereas those in PVLD were located in the central fossa. The 1:1 thickness ratio decreased stresses in both layers of PVZ. Slow cooling slightly decreased residual stresses in both systems. However, the cooling rate effect was more evident in transient stresses.SignificanceSlow cooling is preferable for both systems. A thinner porcelain layer over zirconia lowers stresses throughout the restoration. The different stress distributions between PVZ and PVLD may affect their failure modes. Smaller mismatches in modulus, CTE, and specific heat between the constituents, and the use of low T_g porcelains can effectively reduce the deleterious transient and residual tensile stresses in bilayer restorations.     

Off-axis sliding contact reliability and failure modes of veneered alumina and zirconia

ObjectiveAll-ceramic dental crowns are popular because of their esthetics and biocompatibility. However, they often chip or fracture when subjected to repeated occlusal loading. Considerable efforts to improve the materials are being done through the study of fatigue and failure modes. The vast majority of fatigue studies have been conducted with uniaxial loading and no sliding action. We hypothesized different failure modes for porcelain veneered Y-TZP and that the reliability of porcelain veneered Y-TZP is higher than that of porcelain veneered alumina when subjected to fatigue under 30° off-axis sliding Y-TZP and alumina plates were porcelain veneered and cemented to aged composite blocks as a model for an all-ceramic crown on dentin.MethodsSpecimens (n = 21 per group) were fatigue at 30° off-axis with a hard sphere sliding contact in water, by means of a mouth-motion simulator apparatus.ResultsAlthough no difference between groups was found, the failure modes differed and there was a tendency to higher reliability for Y-TZP compared to alumina for a mission of 50,000 cycles at 150 N load.SignificanceFailure modes for alumina specimens were deep penetrating partial cone cracks and cementation internal surface radial cracks. Y-TZP specimens showed only surface damage with deep penetrating partial cone cracks extending to the veneer core interface, with no cementation surface radial cracking, which overall agrees with clinical finding. Angled sliding contact appears to better simulate oral function.     

In vitro failure and fracture resistance of veneered and full-contour zirconia restorations

ObjectivesThis study evaluated the failure and fracture resistance of zirconia-based fixed partial dentures (FPDs) under the influence of different surface treatments and adjustment procedures.MethodsSeven groups (n = 8/group) of three-unit zirconia-based FPDs were fabricated in anatomic design (AD) or anatomically reduced design (ARD) and surfaces were prepared according to clinical relevance: #1: AD – sintered; #2: AD – sintered – glazed; #3: AD – sintered – sandblasted – glazed; #4: AD – sintered – polished – grinded (contact points adjusted); #5: AD – sintered – polished – grinded – repolished; #6: ARD – sintered – veneered; #7: control: analogous to #3 but without thermal cycling (TC) and mechanical loading (ML). FPDs were adhesively bonded to polymethylmethacrylate abutment teeth. TCML (TC: 6000 × 5°/55°; ML: 1.2 × 10⁶ × 50 N, 1.6 Hz) was conducted in a chewing simulator with steatite spheres as antagonists. Failures were monitored and fracture resistance was determined after ageing. Data were analysed statistically with Mann–Whitney U-test (Kolmogorov–Smirnov-test; α = 0.05). FPDs were subjected to scanning electron microscopy for fractographic failure analysis.ResultsNone of the FPDs failed during TCML, but showed wear at contact points. Median fracture force ranged between 1173.5 N (#4) and 1316.0 N (#3) without significant (p = 0.910) differences between the groups or in comparison to the control (p > 0.462).ConclusionsZirconia restorations showed high resistance to failures and fracture under different surface treatment variations. Full-contour polished or glazed zirconia FPDs might be an alternative to common veneered restorations.