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.

Surface modification for enhanced silanation of zirconia ceramics.

OBJECTIVE: The overall goal of this research was to develop a practical method to chemically modify the surface of high strength dental ceramics (i.e. zirconia) to facilitate viable, robust adhesive bonding using commercially available silanes and resin cements. METHODS: Investigation focused on a novel approach to surface functionalize zirconia with a Si(x)O(y) "seed" layer that would promote chemical bonding with traditional silanes. ProCAD and ZirCAD blocks were bonded to a dimensionally similar composite block using standard techniques designed for silica-containing materials (silane and resin cement). ZirCAD blocks were treated with SiCl4 by vapor deposition under two different conditions prior to bonding. Microtensile bars were prepared and subjected to tensile forces at a crosshead speed of 1 mm/min scanning electron microscopy was used to analyze fracture surfaces and determine failure mode; either composite cohesive failure (partial or complete cohesive failure within composite) or adhesive failure (partial or complete adhesive failure). RESULTS: Peak stress values were analyzed using single-factor ANOVA (p<0.05). Microtensile testing results revealed that zirconia with a surface treatment of 2.6 nm Si(x)O(y) thick "seed" layer was similar in strength to the porcelain group (control). Analysis of failure modes indicated the above groups displayed higher percentages of in-composite failures. Other groups tested had lower strength values and displayed adhesive failure characteristics. CONCLUSION: Mechanical data support that utilizing a gas-phase chloro-silane pretreatment to deposit ultra-thin silica-like seed layers can improve adhesion to zirconia using traditional silanation and bonding techniques. This technology could have clinical impact on how high strength dental materials are used today.