Fixed partial dentures: all-ceramics, fibre-reinforced composites and experimental systems

Computation of the fracture probability and lifetime of all ceramic anterior crowns under cyclic loading - An FEA study

OBJECTIVES

To predict the lifetime and fracture probability of anterior crowns made of a lithium disilicate glass-ceramic (IPS e.max CAD, LD, Ivoclar Vivadent, Liechtenstein) and a zirconia-containing lithium silicate glass-ceramic (Celtra Duo, ZLS, Dentsply Sirona, USA) under cycling loading.

METHODS

Three-point bending tests were conducted to measure the viscoelastic parameters. These parameters are used to compute the residual stresses of the anterior crown after crystallization. In the next analysis, the cyclic loading on the anterior crown was calculated. Based on this combined stress state (residual stress and stress state due to external cyclic loading), the life cycle and fracture probability of the anterior crown was calculated using the CARES/Life software. Finally, fatigue experiments were carried out to compare and validate the results of the computations.

RESULTS

Although a sound qualitative comparison of the lifetime of both materials can be done using this methodology, the calculated fracture probability of the anterior crown for both materials was very low in comparison with the fatigue test results using the fatigue parameters determined from the experiments. In order to achieve good correspondence with the experimental results, the SCG exponent n for both materials should be modified by a correlation factor of 0.38.

SIGNIFICANCE

Using this modified computational strategy, the results of the time-consuming fatigue tests for dental glass-ceramics can be closely predicted. This methodology can be integrated into the development process of new glass-ceramic materials in order to save time and costs.

Fatigue resistance of all-ceramic fixed partial dentures - Fatigue tests and finite element analysis

OBJECTIVE

To estimate the fatigue resistance of a new translucent zirconia material in comparison to lithium disilicate for 3-unit fixed partial dentures (FPDs).

METHODS

Eighteen 3-unit FPDs (replacement of first upper molar) with a connector size of 4mm×4mm were dry milled with a five-axis milling machine (Zenotec Select, Wieland, Germany) using discs made of a new translucent zirconia material (IPS e.max ZirCAD MT, Ivoclar Vivadent). Another 9 FPDs with a reduced connector size (3mm×4mm) were milled. The zirconia FPDs were sintered at 1500°C. For a comparison, 9 FPDs were made of IPS e.max Press, using the same dimensions. These IPS e.max Press FPDs were ground from a wax disc (Wieland), invested and pressed at 920°C. All FPDs were glazed twice. The FPDs were adhesively luted to PMMA dies with Multilink Automix. Dynamic cyclic loading was carried out on the molar pontic using Dyna-Mess testing machines (Stolberg, Germany) with 2×10⁶ cycles at 2Hz in water (37°C). Two specimens per group and load were subjected to decreasing load levels (at least 4) until the two specimens no longer showed any failures. Another third specimen was subjected to this load to confirm the result. All the specimens were evaluated under a stereo microscope (20× magnification). The number of cycles reached before observing a failure, and their dependence on the load and on the material, were modeled, using a Weibull model. This made it possible to estimate the fatigue resistance as the maximum load for which one would observe less than 1% failure after 2×10⁶ cycles. In addition to the experimental study, Finite Element Modeling (FEM) simulations were conducted to predict the force to failure for IPS e.max ZirCAD MT and IPS e.max Press with a reduced cross-section of the connectors.

RESULTS

The failure mode of the zirconia FPDs was mostly the fracture of the distal connector, whereas the failure mode of the lithium disilicate FPDs observed to be the fracture of the connectors or multiple cracks of the pontic. The fatigue resistance with 1% fracture probability was estimated to be 488N for the IPS e.max ZirCAD MT FPDs (453N for repeated test), 365N for IPS e.max ZirCAD MT FPDs with reduced connector size and 286N for the e.max Press FPDs. All three IPS e.max ZirCAD groups statistically performed significantly better than IPS e.max Press (p<0.001). On the other hand, no significant difference could be established between the two IPS e.max ZirCAD MT3 groups with a 4mm×4mm connector size (p>0.05). The allowable maximum principal stress (σ_max) which did not lead to failure during fatigue testing for IPS e.max ZirCAD MT3 was calculated between 208MPa and 223MPa for FPDs with 4mm×4mm connectors for 2×10⁶ cycles. This value could also be verified for the FPDs of the same material with 3mm×4mm connectors. On the other hand fatigue strength in terms of σ_max at 2×10⁶ cycles of IPS e.max Press was calculated to be between 78 and 90MPa.

SIGNIFICANCE

The fatigue resistance of the translucent zirconia 3-unit FPDs was about 60-70% higher than that of the lithium disilicate 3-unit FPDs, which may justify their use for molar replacements, provided that a minimal connector size of 4mm×4mm is observed. Even with a limited number of specimens (n=9) per group it was possible to statistically differentiate between the tested groups.

Zirconia in fixed prosthesis. A literature review

Statement of problem: Evidence is limited on the efficacy of zirconia-based fixed dental prostheses. Objective: To carry out a literature review of the behavior of zirconium oxide dental restorations. Material and Methods: This literature review searched the Pubmed, Scopus, Medline and Cochrane Library databases using key search words “zirconium oxide,” “zirconia,” “non-metal restorations,” “ceramic oxides,” “veneering ceramic,” “zirconia-based fixed dental prostheses”. Both in vivo and in vitro studies into zirconia-based prosthodontic restoration behavior were included. Results: Clinical studies have revealed a high rate of fracture for porcelain-veneered zirconia-based restorations that varies between 6% and 15% over a 3- to 5-year period, while for ceramo-metallic restorations the fracture rate ranges between 4 and 10% over ten years. These results provoke uncertainty as to the long-term prognosis for this material in the oral medium. The cause of veneering porcelain fractures is unknown but hypothetically they could be associated with bond failure between the veneer material and the zirconia sub-structure.

Key words:Veneering ceramic, zirconia-based ceramic restoration, crown, zirconia, tooth-supported fixed prosthesis.

Fracture and shear bond strength analyses of different dental veneering ceramics to zirconia

The purpose of this work was to evaluate the interaction of different layering porcelains with zirconia via shear bond strength test and microscopy. Four different groups of dental veneering porcelains (VM9, Zirkonzanh, Ceramco, IPS) were fused onto forty zirconia-based cylindrical substrates (8mm in diameter and 12 mm in height) (n=10), according to the manufacturer's recommendations. Additionally, layered dental porcelain (D-sign, Ivoclar) was fired on ten Ni-Cr cylindrical substrates Shear bond strength tests of the veneering porcelain to zirconia or Ni-Cr were carried out at a crosshead speed of 0.5mm/min. After the shear bond tests, the interfaces were analyzed by scanning electron microscopy (SEM). The fracture type exhibited by the different systems was also assessed. The results were statistically analyzed by ANOVA at a significant level of p<.05. The shear bond strength values of the porcelain-to-NiCr interfaces (25.3±7.1 MPa) were significantly higher than those recorded for the following porcelain-to-zirconia systems: Zirkonzanh (18.8±1 MPa), Ceramco (18.2±4.7 MPa), and IPS (16±4.5 MPa). However, no significant differences were found in the shear bond strength values between the porcelain-to-NiCr and porcelain (VM9)-to-zirconia (23.2±5.1 MPa) groups (p>.05). All-ceramic interfaces revealed mixed failure type, cohesive in the porcelain and adhesive at the interface. This study demonstrated that all-ceramic systems do not attain yet the same bond strength standards equivalent to metal-ceramic systems. Therefore, despite the esthetic appeal of all-ceramic restorations, the adhesion between the porcelain and zirconia framework is still an issue considering the long term success of the restoration.

A new method to test the fracture probability of all-ceramic crowns with a dual-axis chewing simulator

OBJECTIVES

The purpose of this study was to validate a new laboratory method to test all-ceramic systems with regard to the proportion of failures.

METHODS

Sixteen standardized mandibular molar crowns consisting of two different materials (IPS Empress, IPS e.max Press) were adhesively luted on CAD/CAM milled PMMA abutments (first lower molar, circular chamfer). All crowns were loaded applying an eccentric force in a Willytec chewing simulator (steel stylus, Ø 2.4 mm, 2 mm lateral movement from fossa to cuspal tip) with stepwise increase of the load (3, 5, 9 kg, 100,000 cycles each, 0.8 Hz) and simultaneous thermocycling (5°C/55°C×417 per phase). Another four crowns of each material were subjected to force measurements with a 3D force sensor during dynamic loading of each loading phase using two different lateral movements (from fossa to cusp and vice versa).

RESULTS

The cumulative forces for the three directions in space were much higher compared to the static load of the chewing simulator (maximal force at 3 kg 60 N, 5 kg 160 N, 9 kg 240 N). There was no statistically significant difference in the mean or maximal force between the two materials or two different lateral movements. During dynamic loading, no fractures occurred in the molar crowns made of IPS e.max Press, whereas 50% of the IPS Empress crowns showed failures (75% fractures and 25% chippings) (log-rank test p=0.002). Most of the Empress crowns fractured during the third loading phase (9 kg).

CONCLUSIONS

The forces that the dead weights exerted during dynamic loading were 2-3 times higher than those during static loading. None of the lithium disilicate ceramic molar crowns fractured, whereas half of the leucite reinforced molar crowns failed during dynamic loading.

Fracture frequency of all-ceramic crowns during dynamic loading in a chewing simulator using different loading and luting protocols

OBJECTIVE

The purpose of this laboratory study was to compare the frequency of failures (complete fractures or partial cracks) of molar crowns made of two different all-ceramic materials during dynamic loading in a chewing simulator, as well as the fracture load when subjected to static loading, in relation to different dynamic loading and luting protocols.

METHODS

One hundred and forty-four molar crowns fabricated with IPS Empress or an experimental e.max Press material with high translucency (e.max Press Exp) were luted on CAD/CAM milled PMMA abutments (first lower molar, circular chamfer) either with Variolink or glass-ionomer cement (GIC). All crowns were loaded according to three different loading protocols (n=12 per group) and two force profiles (sinusoidal, rectangular) in a pneumatically driven chewing simulator with a steel stylus (Ø 8 mm) and they underwent simultaneous thermocycling (5 degrees C/55 degrees C). After each phase the crowns were evaluated with regard to fractures or cracks. After dynamic testing, the crowns that did not fail were subjected to compression loading until complete fracture in a universal testing machine (UTM). As control groups, unloaded crowns were also subjected to a UTM. Survival statistics with log-rank tests were applied for the results of the dynamic loading, while ANOVA with post hoc Tukey B was used for the fracture load results and two-way ANOVA was carried out for logarithmically transformed data. Weibull statistics were calculated for pooled fracture load data of the dynamically loaded and control groups.

RESULTS

In the 144 IPS Empress crowns, complete fractures were observed in 9 crowns and partial cracks in another 3 crowns. When the data was pooled, a statistically significant increase in fractures occurred when the sinusoidal force profile was applied compared to a rectangular force profile (log-rank, p<0.05). No fractures occurred in the e.max Press Exp crowns. The two-way ANOVA showed that the type of luting protocol used had the most significant effect on the fracture load of both materials. In conjunction with Empress, however, the luting material influenced the variability twice as much as in e.max Press Exp. There was no statistically significant difference in the fracture load of GIC-luted e.max Press Exp crowns and that of the Variolink luted Empress crowns. The force profile had a significant effect on the fracture load only of the Empress crowns but not of the e.max Press Exp crowns. Weibull statistics revealed a higher scattering of the data of dynamically loaded crowns compared to that of the control groups.

CONCLUSIONS

For testing all-ceramic materials, dynamic loading is indispensable to draw valid conclusions on clinical performance of all-ceramic molar crowns. A sinusoidal profile is advisable, while a gradual increase of the force amplitude does not significantly affect the results.

Fracture resistance of the veneering on inlay-retained zirconia ceramic fixed partial dentures

AIMS

The aim of this in vitro study was to evaluate the fracture load of zircon frames veneered with a polymer glass holding box inlay-retained fixed partial dentures (FPDs). The influence of the position of the frame and the span length was tested. Additionally, the fracture load values of zircon frames veneered with a press ceramic were evaluated.

MATERIAL AND METHODS

Box inlay cavities were prepared on mandibular molars and premolars. Forty-eight FPDs were manufactured using industrially prefabricated zircon frames veneered with the polymer glass Artglass. Sixteen FPDs received individually manufactured CAD/CAM zircon frames veneered with a press ceramic. All FPDs underwent thermal cycling and mechanical loading (ML). The load to fracture was measured and fracture sites were evaluated.

RESULTS

Four polymer veneered FPDs showed fractures in the veneering material after ML. The mean fracture resistance ranged from 531 N to 727 N. No significant influence of frame localization could be observed. Significantly greater fracture resistance values were found in the ceramic veneered FPDs (1276 N to 1413 N). There was no significant effect of span length in the polymer veneered group or in the all-ceramic group, with the exception of a significant peak in fracture load value for intermediate span lengths in the polymer group with a localized occlusal zircon frame.

CONCLUSIONS

Polymer veneered FPDs with Y-TZP frames showed acceptable fracture resistance values, but they cannot yet be unreservedly recommended for clinical use. Fracture values for CAD/CAM manufactured Y-TZP frames combined with a press ceramic deserve further clinical investigation.

In vitro fracture resistance of four-unit fiber-reinforced composite fixed partial dentures

OBJECTIVES

The aim of this in vitro study was to investigate the influence of glass fiber-reinforcement on the fracture resistance of four-unit composite fixed partial dentures (FPDs) in the posterior region.

METHODS

A total of 70 FPDs were fabricated of the composites Sinfony, Vita Zeta and Targis. With each material, 10 FPDs were made without glass fiber-reinforcement and 10 were reinforced with the new glass fiber system EverStick. In addition, 10 FPDs were fabricated of the material combination Targis/Vectris. After thermocycling, all FPDs were loaded until failure in a universal testing machine. The FPDs were then cut and cross-sectional areas were examined by scanning electron microscopy (SEM).

RESULTS

The load to fracture of the fiber-reinforced FPDs lay between 615 and 1191 N, which was significantly greater than the values found with unreinforced FPDs (between 178 and 307 N). The highest values were found with the combinations Targis/Vectris (1191 N) and Sinfony/EverStick (1137 N). SEM showed that the FPDs with EverStick reinforcement not only exhibited fracture lines in the fiber-composite interface, but also more often in the area of the fiber-reinforcement than was the case with the FPDs with Vectris reinforcement. The load to fracture was not significantly dependent on fiber quantity or course of fracture.

SIGNIFICANCE

It may be concluded that the fracture resistance of four-unit composite FPDs can be significantly raised by glass fiber frameworks (p<0.05). The reinforcement effect of EverStick depended significantly on the composite used (p<0.05).

Composite veneering of metal based fixed partial dentures

The aim of this in vitro study was to determine the thermal mechanical properties of veneering composites after polymerization with the appropriate polymerization device. Fracture tests were performed to investigate the effect on fixed partial dentures (FPDs). Dynamic mechanical thermal analysis was used to determine the temperature-dependent mechanical properties. To approximate the clinical situation, the fracture resistance of three-unit metal-based FPDs with different composite veneering was investigated after a simulated 5-year oral wearing period. The restorations were made of a high gold alloy and veneered with three different composites. To determine the influence of fabrication, one composite was used in a light-polymerizing and a heat/pressure-curing version and, in addition, a newly developed heat protection paste was used. After a 5-year simulation period, the fracture resistance was determined. The storage modulus varied between 14268 N mm(-2) (Belleglass) and 6616 N mm(-2) (Sinfony). Adoro showed no significant differences between light curing (9155 N mm(-2)) and heat curing (8184 N mm(-2)) variations. The Adoro-veneering with the heat protection paste showed the highest median fracture strength (1700 N), followed by Adoro LC (1555 N), Belleglass (1051 N), Adoro HP (1150 N) and Sinfony (909 N). The most common failure type occurring in all FPDs was a cracking of the composite, exposing the metal framework. All FPDs showed stress cracking of the composite. The heat protection paste seemed to reduce the crack formation after fabrication and increased the fracture resistance of the composite veneering. Stress cracking after thermal cycling and mechanical loading affected all composites, but all veneered three-unit alloy FPDs showed a fracture resistance sufficient for posterior application.

Adhesive bonding of a lithium disilicate ceramic material with resin-based luting agents

This study evaluates the bonding characteristics of a lithium disilicate-based ceramic material (IPS Empress 2). Two sizes of disk specimens of the material were made, and three groups of disk pairs were separately surface-prepared using three techniques; etching with phosphoric acid, etching with hydrofluoric acid, and air-abrasion with alumina. Each group was further divided into four sub-groups; group (i) was bonded with the Variolink II composite, (ii) was treated with the Monobond-S silane primer and bonded with the Variolink II composite, (iii) was bonded with the Super-Bond acrylic adhesive and (iv) was treated with the Porcelain Liner M silane primer and bonded with the Super-Bond acrylic adhesive. Shear bond strengths were determined before and after 100 000 thermocycles. Bond strength varied from 10.6 to 71.5 MPa before thermocycling, whereas post-thermocycling bond strength ranged from 0 to 61.2 MPa. Among the three surface preparations, hydrofluoric acid etching (HF) was most effective in enhancing bond strength of both luting materials, especially for unsilanized specimens. Application of the silane primer elevated bond strength of both luting agents regardless of surface preparation method. It can be concluded, for both luting agents, that durable bond to the Empress 2 ceramic material can be achieved through the combined application of HF and the proprietary silane primer.