The effect of margin thickness, degree of convergence and bonding interlayer on the marginal failure of glass-simulated all-ceramic crowns

The objectives of this study were to identify the effect of design parameters, namely marginal thickness, degree of convergence and the different interfacial conditions, on the initial failure load that induces cracking from the margin in glass-simulated dental crowns. Crown-like glass cylinders were prepared to simulate posterior all-ceramic crowns with two different marginal thicknesses (0.8 or 1.2 mm) and degrees of convergence (6° or 12°). A three-step bonding system was used complementarily with a silane coupling agent to adhesively bond the specimens to resin dies. The crowns were subjected to an axial applied load to generate hoop tensile stress at the crown margin. The entire loading and fracture processes were recorded by video camera. The loading data were compared with the other two interfacial treatments (Vaseline grease and directly poured uncured resin on glass). The Weibull distribution was used to statistically analyze the characteristic failure load and the mean values. The fracture surfaces were fractographically analyzed along with the load–displacement curves, and the degrees of crack stability for each parameter were also identified. It was found that there is no difference in the initial failure load between the different marginal thicknesses in all interfacial conditions. The bonded crowns present more resistance to crack propagation. The higher convergence crown preparation can reduce the initial failure load at the crowns’ margin, which can be resisted by a strongly bonded interface. Clear interactions between margin design parameters and their effects on the stress development and crack propagation are necessary to develop an appropriate design of all-ceramic crowns.