In vitro fracture behavior of ceramic and metal-ceramic restorations

Failed crowns and failure load data were studied to gain insights into the fracture behavior of prostheses under incisal-directed, load-to-failure testing.

Incisor crowns (n = 68) were fabricated: two all-ceramic groups (feldspathic veneer on high-strength core), differing in core design, and two metal-ceramic groups, differing in metal oxidation time (30 seconds v 3 minutes). Crowns were loaded to failure on their incisal edge. Gross visual, microscopic, and elemental microprobe analyses of failed crowns were coupled with Weibull analysis of the failure load data.

Failure loads were higher for the normal oxidation time (TN) than for the extended oxidation time (TE) metal-ceramic crowns (P < .02), but both groups had indistinguishable Weibull moduli indicating the possibility of a common failure origin. Fracture behavior and Weibull results both implicated the oxide layer as being the origin of failure. The ratio of fracture loads (TE/TN) corresponded well with calculated oxide-volume ratios. Failure loads were lower for the all-ceramic than for the metal-ceramic crowns (P < .001). Fifty percent of the all-ceramic crowns failed by delamination of veneering glass alone, leaving a thin layer of residual glass on the core surface. Scanning electron microscope views showed that delamination occurred 10 to 50 microns away from the core-veneer interface. Electron microprobe elemental analysis of the core-veneer interface showed that residual core infiltration glass was not present on the core surface and that chemical alterations in the veneering glass were apparently limited to less than a 2- to 3-microns thick layer.

Failure for both restorative systems involved interfacial stresses with crack propagation occurring at or near the core-veneer interface. The weaker interface in the metal-ceramic system probably resulted from an increase in surface oxide volume, irrespective of any change in its adherence or physical properties. For the ceramic crowns, delamination crack fronts appeared to propagate through chemically unaltered veneering porcelain. Both the Weibull moduli and characteristic strengths were indistinguishable between either of the two ceramic core designs or between groups failing from delamination with or without core cracking/failure. This is consistent with delamination being the primary fracture process during failure. Clinical implications should not be drawn from results of this study because no correlation is known to have ever been established between clinical behavior and incisal load-to-failure results.