Zirconia-parylene multilayer thin films for enhanced fracture resistance of dental ceramics

Recent research has shown that the application of specific thin films can enhance the material properties of a laminate construct. In this study, the effect of different mono/multilayered films on the strength of a ceramic specimen is demonstrated. It is well established that cracks can initiate and/or propagate from the internal surfaces of all-ceramic dental restorations. Modifying that surface by thin-film deposition might help increase clinical longevity and applicability. Specimens were divided into the following groups according to different surface treatments received: uncoated (control group), 10 microm yttria-stabilized zirconia (YSZ) thin film, 10 microm parylene thin film, 9.75 microm YSZ + 0.25 microm parylene film, and a multilayered film (five layers of 1.25 microm YSZ + 0.75 microm parylene). Depositions were performed using a radio-frequency magnetron sputter system (working pressure 15 mT, 150 degrees C, 30:1 Ar/O2 gas ratio) to produce the YSZ layers, and a vapour deposition process was used to produce the parylene layers. Flexural strength measurements were carried out by three-point bending (span = 10 mm) in a servo-electric material testing system in deioinized (DI) water (37 degrees C). The results showed that the strength of the specimen significantly increased with the deposition of all types of coating, showing the greatest increase with the multilayered film (approximately 32 per cent). It is hypothesized that a multilayer thin film (brittle/ductile) can promote crack deflection, causing strength enhancement of the brittle construct.