Surface properties and flexural fatigue strength of an advanced lithium disilicate

The aim of this study was to evaluate the surface properties and fatigue mechanical behavior of an advanced lithium disilicate ceramic in comparison to lithium disilicate and zirconia. First, discs (n = 15, diameter = 13.5 mm and thickness = 1.2 mm) were made from the following materials: 4Y-PSZ - 4% mol yttria-stabilized zirconia (IPS e.max ZirCAD A2); LD - lithium disilicate (IPS e.max CAD); ALD - advanced lithium disilicate (CEREC Tessera). The specimens were crystalized/sintered and subsequently analyzed by a rugosimeter (Mitutoyo SJ-410) to determine surface roughness (parameters Ra and Rz). Specimens were subjected to biaxial flexural fatigue testing using the step-test method (20 Hz; 10,000 cycles per step; initial stress of 200 MPa; and step size of 25 MPa) until specimen fracture. Statistical analyses included Shapiro-Wilk, Kruskal-Wallis, and post-hoc tests for roughness data, while survival analysis (Kaplan-Meier and Mantel-Cox) and reliability analysis (Weibull modulus) were applied to flexural fatigue strength data. Hardness (Vickers) results were submitted to analysis of variance (1-way ANOVA) and Tukey's test. Zirconia (4Y-PSZ) showed higher FFS, CFF (467 MPa and 115216 cycles) and survival compared to the other materials. ALD had the lowest FFS, CFF (215 MPa and 11,908 cycles) and survival. ALD showed lower Weibull modulus (m = 6.63 for FFS; m = 1.27 for CFF) than LD for FFS (m = 17.33), and lower than LD (m = 4.64) and 4Y-PSZ (m = 6.69) for CFF. ALD showed the lowest Ra (0.07 μm) and Rz (1.05 μm) values, while 4Y-PSZ (Ra = 0.22 μm; Rz = 1.91 μm) and LD (Ra = 0.21 μm; Rz = 2.17 μm) showed higher and similar values. Zirconia (4-YPSZ) was the hardest material, while lithia-based ceramics (LD and ALD) presented the lowest and similar hardness values. Fractures originated in surface defects in the tensile stress concentration region. ALD has lower flexural fatigue strength compared to the other tested materials, along with higher variability (lower structural reliability).