Exploring physical and mechanical properties of hydrothermally processed recycled non-sintered dental zirconia wastes

Background and aim The present investigation explored the potential for recycling residual blocks obtained from the machining processes under hydrothermal conditions. Furthermore, the study examined the recycled samples' various physical and mechanical properties to assess their viability for further use. Materials and methods In this in vitro study, Aman Girbach blocks were collected, half of which underwent a hydrothermal process, while the other half did not. The blocks were then subjected to ball milling. Uniaxial and isostatic pressed blocks were prepared, and 10 samples were obtained from each type of recycled block. These samples were compared to a commercial material, and four groups were formed based on the powder type and pressing method used. The quality control analysis of the recycled samples included assessing particle size distribution, identifying crystalline phases, analyzing color differences, examining microstructure, and evaluating mechanical properties. Statistical tests such as normal distribution calculations (k-s test), one-way ANOVA, Brown-Forsythe, Tukey HSD, and Games-Howell tests were used to compare the four groups and perform pairwise comparisons. Results The flexural strength and density of the control commercial group were significantly higher than the other experimental groups (P = 0.000). Linear shrinkage of recycled isostatic pressed experimental bodies was significantly lower than that of others (P = 0.000). Qualitative evaluation of microstructure and crystalline phase by FESEM and XRD showed no significant difference in grain size and crystalline phase between different groups. Conclusion The hydrothermal process is a promising way to recycle zirconia ceramic with lower energy consumption. Recycled waste demonstrates potential as a cost-effective and viable option for ceramic prostheses in situations with low to medium stress levels.