Thermal-induced residual stresses affect the lifetime of zirconia–veneer crowns

Objectives The purposes of this study were to investigate the effects of thermal residual stresses on the reliability and lifetime of zirconia-veneer crowns. Methods One hundred and twenty eight second upper premolar zirconia-veneer crowns were manufactured for testing the initial strength (n=64) and under cyclic fatigue (n=64). Zirconia copings (YZ Cubes, VITA Zahnfabrik, CTE: alphac=10.5 ppm/°C) were milled using a Cerec3 InLab (Sirona) machine and sintered to a final thickness of 0.7 mm. Sixty-four copings were sandblasted with 105 μm alumina particles (15 s, 3 cm distance, 45° angle, 0.4 MPa pressure) in order to trigger a tetragonalmonoclinic transformation and to produce a rough surface. The copings were veneered using two different porcelains (VM9, VITA Zahnfabrik, CTE: alphaVM9=9.1 ppm/°C, Lava Ceram, 3M ESPE, CTE: alphaLava=10.2 ppm/°C) so to result in crowns with either high thermal mismatch (+1.4 ppm/°C with VM9) and low thermal mismatch (+0.3 ppm/°C with Lava Ceram). The porcelains were applied by the same operator and fired (VITA Vacumat 4000) according to the firing schedules defined by the manufacturers to a final thickness of 1.4mm (total crown thickness=2.1mm, core/veneer ratio=0.5). After the last glaze firing the crowns were cooled following a fast (600°C/min) or a slow (30°C/min) cooling protocol. The glazed crowns were submitted to a sliding-motion (0.7 mm lateral movement) cyclic fatigue in a chewing simulator (SD Mechatronik) under 20 kg (~200 N load) weight until failure (chipping) (n=16). The other half of the crowns were subjected to a compressive loading test in an universal testing machine (Instron model 4240) until failure at a cross-head speed of 0.75 mm/min (n=16). The failure probability for initial strength and cyclic fatigue was performed using a Weibull distribution approach at a scale factor of n=16. Results The compressive strength test showed a low sensitivity to detect reliability variations regarding thermal stresses created within the veneer layer of tested crowns. For cyclic fatigue, slow cooling resulted in statistically higher cycles to failure only for the crowns that presented a high thermal mismatch between core and veneer (VM9 group). Comparisons between veneers with high or low thermal mismatches showed statistically higher sigma0 for Lava Ceram-veneered crowns only when the groups were fast-cooled. Significance Minimizing the thermal residual stresses within the veneer through the use of a veneer with a closer CTE to the zirconia delays the failure of zirconia-veneer crowns. Slow-cooling increases the lifetime of crowns presenting large differences in CTE between the zirconia core and the veneering porcelain.