Eigenstrain boundary layer modelling of the yttria-partially stabilised zirconia–porcelain interface in dental prostheses

The exceptional strength and appealing aesthetics of porcelain veneered yttria partially stabilised zirconia (YPSZ) dental prostheses, has led to the widespread adoption of these materials. However, near-interface chipping of the porcelain remains the primary failure mode. Advanced experimental techniques have recently revealed significant variations in residual stress and YPSZ phase distribution at the YPSZ–porcelain interface. Therefore, in order to improve existing understanding and effectively optimise the production of these devices, an enhanced model of the YPSZ coping that includes these newly discovered phenomena is presented in this study. Macroscale stresses are shown to arise through the uneven temperatures within the coping during the sintering process and the coefficient of thermal expansion mismatch with the porcelain during veneering. In contrast, microscale stresses are driven by the YPSZ phase transformation and the associated volumetric expansion. The eigenstrain approach proposed here was found to demonstrate a good match between the phase variation determined experimentally, and the corresponding residual stress distribution showed an effective comparison with the empirical measurements. The proposed technique is a straightforward but powerful method for simulating this dominant mechanical behaviour, with significant potential to combine the resulting expressions into existing models. These enhanced simulations are the only viable approach for the precise, reliable and systematic optimisation of prosthesis production parameters that are needed to significantly reduce prosthesis failure rates.</p

Intragranular residual stress evaluation using the semi-destructive FIB-DIC ring-core drilling method

Titanium aluminide (TiAl) is a lightweight intermetallic compound with a range of exceptional mid-to-high temperature mechanical properties. These characteristics have the potential to deliver significant weight savings in aero engine components. However, the relatively low ductility of TiAl requires improved understanding of the relationship between manufacturing processes and residual stresses in order to expand the use of such components in service. Previous studies have suggested that stress determination at high spatial resolution is necessary to achieve better insight. The present paper reports progress beyond the current state-of-the-art towards the identification of the near-surface intragranular residual stress state in cast and ground TiAl at a resolution better than 5 μm. The semi-destructive ring-core drilling method using Focused Ion Beam (FIB) and Digital Image Correlation (DIC) was used for in-plane residual stress estimation in ten grains at the sample surface. The nature of the locally observed strain reliefs suggests that tensile residual stresses may have been induced in some grains by the unidirectional grinding process applied to the surface. © (2014) Trans Tech Publications, Switzerland

Mechanical microscopy of the interface between yttria-partially-stabilised zirconia and porcelain in dental prostheses

In recent decades, the high strength, high toughness and appealing aesthetics of Yttria-Partially-Stabilised Zirconia (YPSZ) has made this ceramic the material of choice for dental prostheses. During manufacture YPSZ copings are veneered with porcelain to match the appearance of natural teeth and to reduce wear. However, near-interface chipping of the veneer is observed as a persistent primary failure mode. Recent studies suggest that failure is associated with the mechanical and microstructural state within a few microns of the interface. This insight has provided the motivating driver for this study: to develop and implement new characterisation techniques to improve the understanding of the YPSZ-porcelain interface and thereby reduce failure rates. Microscale characterisation of the interface was performed using energy dispersive X-ray spectroscopy, Raman spectroscopy, X-ray Diffraction (XRD) and transmission electron microscopy. These studies indicated that YPSZ phase variation, elemental composition gradients and distinct microstructural features are present within 10 μm of the interface. Porcelain nanoscale voiding was found at the interface, and small angle neutron scattering confirmed that this is induced by tensile creep. High resolution (microscale) residual stress analysis was performed in YPSZ using XRD and Raman spectroscopy, and in porcelain using a new pair distribution function analysis technique. Cross-validation of these results was performed using improved implementations of the ring-core focused ion beam milling and digital image correlation technique. The variation of Young's modulus, yield strength and fracture toughness were determined using spatially resolved micropillar compression and splitting. Improved evaluation of the single-crystal stiffness of YPSZ was also performed using a new neutron diffraction based technique. The results of this analysis indicate a complex interaction within the first 50 &mu;m of the YPSZ-porcelain interface which leads to a significant reduction in porcelain toughness and an increased propensity to fail at this location.</p

Investigations into the interface failure of yttria partially stabilised zirconia - porcelain dental prostheses through microscale residual stress and phase quantification

Objectives: Yttria Partially Stabilised Zirconia (YPSZ) is a high strength ceramic which has become widely used in porcelain veneered dental copings due to its exceptional toughness. Within these components the residual stress and crystallographic phase of YPSZ close to the interface are highly influential in the primary failure mode; near interface porcelain chipping. In order to improve present understanding of this behaviour, characterisation of these parameters is needed at an improved spatial resolution.Methods: In this study transmission micro-focus X-ray Diffraction, Raman spectroscopy, and focused ion beam milling residual stress analysis techniques have, for the first time, been used to quantify and cross-validate the microscale spatial variation of phase and residual stress of YPSZ in a prosthesis cross-section.Results: The results of all techniques were found to be comparable and complementary. Monoclinic YPSZ was observed within the first 10m of the YPSZ-porcelain interface with a maximum volume fraction of 60%. Tensile stresses were observed within the first 150m of the interface with a maximum value of ≈ 300 MPa at 50m from the interface. The remainder of the coping was in mild compression at ≈ − 30 MPa, with shear stresses of a similar magnitude also being induced by the YPSZ phase transformation.Significance: The analysis indicates thatthe interaction between phase transformation, residual stress and porcelain creep at YPSZ-porcelain interface results in a localised porcelain fracture toughness reduction. This explains the increased propensity of failure at this location, and can be used as a basis for improving prosthesis design

Residual strain mapping through pair distribution function analysis of the porcelain veneer within a yttria partially stabilised zirconia dental prosthesis

OBJECTIVE: Residually strained porcelain is influential in the early onset of failure in Yttria Partially Stabilised Zirconia (YPSZ) - porcelain dental prosthesis. In order to improve current understanding it is necessary to increase the spatial resolution of residual strain analysis in these veneers. METHODS: Few techniques exist which can resolve residual stress in amorphous materials at the microscale resolution required. For this reason, recent developments in Pair Distribution Function (PDF) analysis of X-ray diffraction data of dental porcelain have been exploited. This approach has facilitated high-resolution (70μm) quantification of residual strain in a YPSZ-porcelain dental prosthesis. In order to cross-validate this technique, the sequential ring-core focused ion beam and digital image correlation approach was implemented at a step size of 50μm. This semi-destructive technique exploits microscale strain relief to provide quantitative estimates of the near-surface residual strain. RESULTS: The two techniques were found to show highly comparable results. The residual strain within the veneer was found to be primarily tensile, with the highest magnitude stresses located at the YPSZ-porcelain interface where failure is known to originate. Oscillatory tensile and compressive stresses were also found in a direction parallel to the interface, likely to be induced by the multiple layering used during fabrication. SIGNIFICANCE: This study provides the insights required to improve prosthesis modelling, to develop new processing routes that minimise residual stress and ultimately to reduce prosthesis failure rates. The PDF approach also offers a powerful new technique for microscale strain quantification in amorphous materials.</p