Effect of Veneering Methods on Zirconia Framework-Veneer Ceramic Adhesion and Fracture Resistance of Single Crowns

Purpose The aim of this study was to evaluate the fracture resistance (FR) and shear bond strength (SBS) via finite element analysis (FEA) of zirconia framework veneered with different methods. Materials and Methods Zirconia frameworks were prepared as crowns for FR and cubic blocks for SBS (N = 60, n = 10). The specimens were veneered with one of the following veneering methods: (a) overcemented file‐splitting (OCF), (b) layering (L), or (c) overpressing (P). For crowns, stainless steel dies (N = 30; chamfer: 1 mm) were scanned using a contrast spray. Bilayered design for OCF and reduced design (1 mm) for both L and P were performed by computer‐aided design and manufacturing. For the SBS test, zirconia blocks were sectioned (4 × 4 × 4 mm3) under water cooling and sintered. Frameworks were veneered with compatible ceramics for each veneering method and subjected to mechanical tests. The milled suprastructures were bonded to zirconia frameworks using a resin composite in Group OCF and photopolymerized. Crowns were cemented to the metal dies with resin modified glass‐ionomer cement. All specimens were stored at 37°C, 100% humidity for 48 hours prior to mechanical tests. Data were statistically analyzed (ANOVA, Bonferroni tests, α = 0.05). Fractured specimens were examined under scanning electron microscopy (SEM), and FEA modeling of the crowns was performed. Results Mean FR values (N) were significantly higher with L (6102 ± 1519) and P (4117 ± 1083) than with of OCF (1900 ± 254) (p = 0.01). The mean SBS (MPa) in OCF (24 ± 4) was significantly lower (p < 0.002) than L (35 ± 6) and P (32 ± 6) (p > 0.05). For crown restorations, while only adhesive failures were found in OCF, cohesive failures within veneering ceramic were more frequent in P and L. FEA verified these findings. Conclusion Veneering methods based on layering or pressing may reduce ceramic chipping but the overcemented file‐splitting method does not seem to prevent this failure. Clinical Significance Layering and overpressing veneering methods on zirconia frameworks with reduced design might decrease chipping compared to overcemented file‐splitting, where in the latter, zirconia framework and feldspathic suprastructure are combined using a resin cement.