Biaxial flexural strength, crystalline structure, and grain size of new commercially available zirconia-based ceramics for dental appliances produced using a new slip-casting method.

Abstract

The aim of this study was to evaluate the biaxial flexural strength, the crystalline structure, and the grain size of zirconia-based ceramics produced using a new slip-casting method. Yttria-stabilized Tetragonal Zirconia Polycrystal (Y-TZP) and Alumina Toughened Zirconia (ATZ) ceramics were purchased from different manufactures. For the experimental group, ceramics produced using a patent pending slip-casting method (Slurry, Decema GmbH) was used. Slurry ceramics (n = 42) with a diameter of 14 ± 0.2 mm were produced by a proprietary colloidal shaping process, sintered, and subsequently polished with a lapping process using 15 μm diamond particles to a thickness of 1.2 ± 0.2 mm. For the control group, ceramics produced using the hot isostatic pressure method (HIP, Metoxit AG) were used. HIP ceramics discs (n = 42) with a diameter of 15.5 ± 0.02 mm were produced by classical HIP method and subsequently machined to a thickness of 1.99 ± 0.04 mm 32 discs of each ceramic were submitted to a biaxial flexural strength test using an universal testing machine at a crosshead speed of 0.5 mm/min. Statistical analyses using two-way ANOVA and Weibull distribution were performed. 2 discs of each ceramic were analyzed using X-ray diffraction for grain crystalline phase quantification. 2 discs of each ceramic were thermally etched and scanning electron microscopy images were obtained for grain size analysis (ISO 13383-1:2012). 6 discs of each ceramic were used for density measurement using the Archimedes' method. For both ATZ and Y-TZP ceramics, the biaxial flexural strength and the characteristic strength of ceramics produced using the Slurry method were significantly higher than ones of the ceramic produced using HIP. The structure analysis confirmed the superiority of the Slurry ceramics which had only 1.2% tetragonal phase compared to 11-16% for the HIP ceramics. Grain size distributions covered a wide range 50-800 nm; the ZrO₂ grains of the Slurry ceramics were significantly smaller than the ones of the control ceramics, while the Al₂O₃ grain distributions were not affected by the manufacturing process. The manufacturing process had no influence on the density of both materials. The Slurry method using a new proprietary slip-casting method to produce Y-TZP and ATZ dental ceramics presented higher biaxial flexural strength, less monoclinic phase and smaller ZrO₂ grains.