Fatigue limits and SEM/TEM observations of fracture characteristics for three Pd-Ag dental casting alloys

The fatigue limits and fracture characteristics for three Pd-Ag dental casting alloys (Super Star, Heraeus Kulzer; Rx 91, Pentron; W-1, Ivoclar Vivadent) were studied. Specimens meeting the dimensions for ADA Specifications No. 5 and 38, and having the as-cast surface condition, were subjected to heat treatment simulating dental porcelain firing cycles and fatigued in air at room temperature under uniaxial tension-compression at 10 Hz. A ratio of compressive stress amplitude to tensile stress amplitude (R-ratio) of -1 was used. Alloy microstructures and fracture surfaces were examined with a scanning electron microscope and a transmission electron microscope. Fatigue limits for the three alloys had low values of approximately 15% of the yield strength for 0.2% permanent tensile strain. Complex fracture surfaces with characteristic striations were observed for all three fatigued alloys. Planar slip of dislocations occurred in the Pd solid solution matrix, along with dislocation-precipitate interactions and dislocation networks in the interfaces between the precipitates and surrounding matrix. Twinning occurred in the Pd solid solution matrix of Rx 91, and within discontinuous precipitates in Super Star and Rx 91. The low fatigue limits for these alloys are attributed to their complex microstructures and perhaps to casting defects.