Influence of zirconia surface treatments of a bilayer restorative assembly on the fatigue performance

Purpose This study evaluated the influence of different surface treatments of zirconia used to enhance bonding with veneering porcelain, and thermocycling on the resistance to porcelain cracking and delamination during fatigue test. Methods Bilayer ceramic discs were made from zirconia blocks (IPS e.max Zircad MO, Ivoclar Vivadent - 0.7 mm thickness) and randomized into 8 groups (n= 15) according to two factors: 'zirconia surface treatment' (Control; Grinding - diamond bur; Air-abrasion - aluminum oxide particles; and Liner - application of a ceramic liner [IPS e.max Zirliner, Ivoclar Vivadent]); and 'thermocycling' (presence - 12,000 thermal cycles; 5-55oC; or absence). The discs were veneered with porcelain (IPS e.max Ceram, Ivoclar Vivadent - 0.7 mm; totaling 1.4 mm thickness) according to ISO 6872:2015 for biaxial flexure strength testing. Fatigue tests (step-stress approach; 20 to 100 MPa; step of 10 MPa; 10,000 cycles per step; 10 Hz frequency) were run, followed by the data analysis (Kaplan-Meier and Mantel-Cox post-hoc tests). Analysis of roughness, topography, crystallographic phase arranges and fractography were also executed. Results The surface treatment and thermocycling did not influence the porcelain crack nor delamination resistance. When only comparing the surface treatments for crack resistance outcome, the liner application depicted the worst fatigue performance in comparison to grinding and air-abrasion, while all groups were similar for delamination. Conclusions Neither the surface treatment of the zirconia nor the thermocycling influences the porcelain crack resistance or the resistance to delamination of the bilayer porcelain-veneered zirconia specimens.