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seminar13-allceramics-160714175323
seminar13-allceramics-160714175323
• Composition • Conclusion
• Manufacture
• Fabrication
• Ceramic is derived from the Greek word ‘keramos’, which means ‘potter's clay’.
• Earliest techniques consisted of shaping the item in clay/soil and then baking it to fuse the
particles together, which resulted in coarse and porous products.
• A specially formulated ceramic material that exhibits adequate strength, durability and
color that is used intraorally to restore anatomic form and function, and/or esthetics.
Compounds of one or more metals with a non metallic element (usually silicon,
boron, oxygen) that may be used as a single structural component or as one of the
several layers that are used in the fabrication of a ceramic based prosthesis.
• PORCELAIN
• COPY-MILLING
• A process of machining a structure using a device that traces the surface of master
metal, ceramic, or polymer pattern and transfers the traced spatial positions to a
cutting station where blank is cut or ground in a manner similar to key-cutting
procedure.
• SINTERING
• The process of heating closely packed particles to achieve interparticle bonding and
sufficient diffusion to decrease the surface area or increase the density of the
structure.
All Ceramics – Dr. Nithin Mathew 7
• VITRIFICATION :
• GREEN STATE :
• A term referred to as pressed condition before sintering.
• SPINEL :
Firing temperature
Use / Indications
Fabrication techniques
Crystalline phases
Microstructure
Translucency
According to system
Opaque Glass
Translucent Crystalline
Pure alumina
Core porcelain
Pure Zirconia
Silica glass Body porcelain
Spinelle
Leucite based glass ceramic Enamel porcelain
• Primary constituent
Feldspar • Minerals composed of potash (K₂O), soda(Na₂O) and silica (SiO₂)
• 75-85%
• 4-5%
• Increases the moldability of the plastic porcelain
Kaolin • Serves as a binder
• Consists of Al₂O₃ 2SiO₂ 2H₂O (Hydrated Aluminium Silicate)
• Kaolin is opaque and can lower the translucency of porcelain
Highly esthetic
Biocompatibility
Electrical Resistance
Thermal Insulation
Wear resistance
Brittleness
• Ceramic raw materials are mixed together in a refractory crucible and heated to a
temperature well above their fusion temp
MgO MgF2 CaF2
• Series of reactions occur. CaCO3
Al2O3 BaCO3
SiO2
P2O5
• Flux reacts with the outer layers of silica, kaolin and feldspar
• The process of blending, melting and quenching the glass is called FRITTING
MgF2 CaF2
MgO CaCO3
Al2O3 BaCO3
SiO2
P2O5
Crucible
All Ceramics – Dr. Nithin Mathew 28
MgO MgF2 CaF2
CaCO3
Al2O3 BaCO3
SiO2
P2O5
Melting Quenching
MANUFACTURING OF CERAMICS
Sieving
Frit
• Crystalline Phase
• Added to improve the mechanical properties
• Newer ceramics (35-90%)
• Shade guide
CONDENSATION :
• Padding or packing of wet porcelain into position
• The movement of particles is generated by vibration, spatulation or whipping, brush
technique and spray opaquing.
• Cut-back
• Condensation methods:
• MANUAL CONDENSATION
• ULTRASONICCONDENSATION
• Reduces the fluid content of layered ceramics; resulting in denser and more vibrant porcelain
mass.
• Process of heating closely packs particles to achieve interparticle bonding and sufficient
diffusion to decrease the surface area or increase density of the structure.
• Steps:
• Placing the porcelain object on a tray in front of a preheated furnace at 650C for 5min for low
fusing porcelain and at 480C for 8min for high fusing porcelains till reaching the green or
leathery state.
• Significance:
According to
temperature According to the media
presetting: employed for firing:
Bisque bake
A series of stages of maturation in the firing of ceramic materials depending on the degree of
pyrochemical reaction and sintering shrinkage occurring before vitrification (glazing).
• Low bisque
• Medium bisque
• High bisque
• Medium bisque
• Surface is still porous but the flow of the glass grains is increased and entrapped air
will become sphere shaped.
• High bisque
• Produces smooth, shiny and impervious outer layer, also effective in reducing
crack propagation.
• 2 ways :
• Add-on glazing
• Self glazing – most preferred technique
COOLING :
• Carried out slowly
• Rapid cooling results in cracking or fracture of glass and loss of strength.
• After firing, placed under a glass cover to protect it from air current and
contamination by dirt.
All Ceramics – Dr. Nithin Mathew 41
Porcelain Surface Treatment
Natural or Autoglaze
• Porcelain has the ability to glaze itself when held at its fusing temperature in air for 1-4
mins.
• Porcelain loses its ability to form a natural glaze after multiple firings
Applied Overglaze
• Applied overglaze is a low fusing clear porcelain painted on to the restoration and fired at
a fusing temperature much lower than that of the dentin and enamel porcelain.
Sequence Instruments
• Ion exchange
• Thermal tempering
• Dispersion strengthening
• Transformation toughening
• Stress raisers are discontinuities in ceramic and metal ceramic structure that causes stress
concentration.
• Restoration should be designed in such a way that it avoids exposure of ceramic to high tensile
stresses.
• The coefficient of thermal contraction of metal should be slightly higher than that of porcelain.
• Metal contracts slightly more than the porcelain on cooling from firing temperature to room
temperature
• Leave porcelain in residual compression and provides additional strength for the prostheses.
• Leucite is a high expansion crystal phase which affects the thermal contraction coefficient of
porcelain.
• Increasing the no. of firing cycles can increase the LCTE of veneering porcelain. This leads to
stresses on cooling.
• Since potassium ion is 35% larger than sodium ion, squeezing of the potassium ion creates
very large residual compressive stresses.
• Creates residual compressive stresses by rapidly cooling the surface of the object while it is in
the molten state.
• The solidifying molten core as it shrinks, creates residual compressive stress within the outer
surface.
• When crystalline material such as alumina (Al₂O₃) is added to a glass, the glass is
strengthened and crack propagation does not take place easily.
• This method also relies on dispersion of a crystalline material within the ceramic.
• Strengthening occurs due to a change in the crystal structure under stress which prevents
crack propagation.
• Dental ceramics based primarily on zirconia crystals when heated to a temperature between
1470°C and 2010°C undergo change in the crystal structure from tetragonal to a monoclinic
phase at approx. 1150°C
• Castable Ceramics
• Pressable Ceramics
• Machinable Ceramics
• Inadequate translucency
• O’Brien in 1984
• High expansion ceramics
• Core material
• Crystalline magnesia (40-60%) ‘Forsterite’.
• Magnesia crystals strengthen glass matrix by both dispersion strengthening and crystallization
within the matrix .
• The leucite and glassy components are fused during the baking process at 10200C.
• Translucency : Closeness of the refractive index of leucite with that of the glass matrix.
• Good translucency
• Fracture in posterior teeth.
• Fabrication:
• Powder mixed with water to form suspension called “SLIP”
• SLIP is painted onto refractory die : absorbs water – leaving solid alumina
• Baked at 11200C for 10 hours : opaque, porous core
• Glass powder applied to core and fired at 11000C for 3-4hrs
• Molten glass infiltrates the porous alumina or spinel by capillary action
• Veneering
All Ceramics – Dr. Nithin Mathew 66
Mixing aluminous powder with water to The slip is painted onto the die
Die preparation
produce slip with a brush
• Since the density of In-ceram core makes conventional methods of etching with HF acid
ineffective for bonding with a resin-cement.
• Developed by a French scientist and dentist Dr. Michael Sadoun (1980) and first introduced in
France in 1988.
Composition:
Fabrication stages :
• Slip casting
• Veneering of core
STRENGTH :
• Densely packed crystalline particles (70% alumina) limit crack propagation and prevent
fracture.
COLOR :
• Colorants used : transitional metal ions incorporated into the glass structure itself
• Spinel ceramic : the core is more transparent and its corresponding infiltration glass is slightly
tinted.
• Increased translucency
• Spinel or Magnesium aluminate (Mg A12O4) is a composition containing A12O3 and Mg2O.
characteristics.
• 25% reduction in flexural strength.
• Physical properties were improved without altering the proven working procedure.
• 30 wt% zirconia
• 70 wt% alumina.
• Biocompatibility
79
• Di-Cor
• New types
• Cera pearl
• Canasite glass ceramic
• Optimal pressable ceramic
• Olympus castable ceramics
• Castable phosphate glass ceramic
• Steps:
• Wax pattern – invested
• Dewaxing
• Molten glass cast into mould using centrifugal casting machine
• Glass core : ceramming (heat treatment process)
• Microscopic plate-like crystals grow within the glass matrix
• Veneered using feldspathic ceramics : Dicor Plus
• Non porous, non homogenous, microstructure with uniform crystal size which is derived from
the controlled growth of crystals within an amorphous matrix of glass.
Supplied as :
• Special Dicor casting crucibles, 4.1 gm Dicor glass ingot
• Dicor shading porcelain kit.
• Biocompatible
• Less bacterial counts : smooth surface, low surface tension, fluoride content.
Esthetics :
• Chameleon effect i.e. the restoration acquires a part of the color from adjacent teeth and
fillings as well as the underlying cement lute.
Cementation :
• Zinc phosphate, light activated urethane resin
• Etching with ammonium difluoride for 2 min (Bailey & Bennet 1988)
Survival rate :
• Kenneth et al 1999 - 14yr study
• Crowns : 82%
• Cores : 100%
• Inlay and onlay : 90%
• Partial coverage : 92%
Hydroxy Exposed to
Apatite moisture
Ceramming :
The ceramming oven is preheated at 750°C for 15 minutes. After the cast glass ceramic is
placed in the oven the temperature is raised at the rate 500C / min until it reaches 870°C and held
for 1 hr.
92
• Fabricated using Lost Wax technique and heat pressed into the mould
• Steps:
• Wax pattern – invested in phosphate bonded investment
• Placed in specialized mould with alumina plunger
• After burnout, ceramic ingot is placed under plunger and heated to 11500C
• Veneered using feldspathic ceramics
(900-13000C)
• Al2O3 + MgO MgAl2O4 (decreased shrinkage )
• Biocompatible
• Dimensional stability of the core material in the molded (unfired) and fired states
• Better accuracy of fit and marginal integrity
• Esthetics
• Biocompatible (inert) and resistant to plaque formation (glazed surface)
• Radio density similar to that of enamel
• Low thermal conductivity; thus reduced thermal sensitivity
• Low coefficient of thermal expansion and high modulus of elasticity results in protection of
cement seal
• Poor abrasion resistance, hence not recommended in patients with heavy bruxism or
inadequate clearance
• LIMITATIONS and high clinical failure rates of the Cerestore led to the withdrawal of this
product from the market.
• 2 types:
• Contains higher concentration of leucite crystals, which increases the resistance to crack
propagation
All Ceramics – Dr. Nithin Mathew 102
FABRICATION
Lost-wax technique:
• Etch-able
• Biocompatible material
• Special laboratory equipment such as pressing oven and die material (expensive)
• Inability to cover the color of a darkened tooth preparation or post and core, since the crowns
are relatively translucent.
• Compressive strength and flexural strength lesser than metal-ceramic or glass-infiltrated (In-
Ceram) crowns.
• The apatite crystals are layered which improved optical properties (translucency, light
scattering) which contribute to the unique chameleon effect.
Flexural
Upto 150 MPa > 400 Mpa
strength
Advantages
• High biocompatibility
• Excellent fracture resistance
• High radiopacity
• Outstanding translucency
• Introduced in 2005.
Impression
Data Contact
Camera Laser
Acquisition Digitizer
Casts & Die
Restoration Computerised
Design Wax Pattern
Design
Investing Electrical
Restoration Machine Discharge
Sinter
Fabrication Machine
Casting
• Combined group effort between the University of Zurich and Brains, Brandestini
Instruments of Switzerland.
• Optical impression - Photograph based system using a 35-mm camera with magnifying lens.
• Data processing - Data obtained in the dental office is sent to another location for processing
and machining.
I. Copy milling
I. Direct
i. Fabrication of prototype for scanning
II. Indirect
ii. Copying and reproduction by milling
i. 3-D scanning
II. Erosive techniques
ii. CAD modelling
i. Sono Erosion
iii. Fabrication
ii. Spark Erosion
CAD-CAM:
• Uses digital information about the tooth preparation or a pattern of the restoration to provide
a computer-aided design (CAD) on the video monitor for inspection and modification.
• The image is the reference for designing a restoration on the video monitor.
• Once the 3-D image for the restoration design is accepted, the computer translates the image
into a set of instructions to guide a milling tool [CAM] in cutting the restoration from a block of
material.
• The last two stages are more complex and are still being developed for including in
commercial systems.
• Milling device generates a precision fitting restoration from a standard ceramic block
• Consists of:
• 3-D video camera (scan head)
• Electronic image processor with memory unit
• Digital processor
• Miniature Milling machine
• Inaccuracies in fit
• Quality of ceramic is not changed during
processing
• Poor esthetics systems
• DURET SYSTEM
• Francois Duret : produced by Sopha (France)
• CICERO SYSTEM
• COMET SYSTEM
• Single visit
• Good patient acceptance
• Eliminates procedures like impression model making and fabrication of temporary prosthesis
• Void free porcelains without firing shrinkage
• Better adaptation
• Inlay, onlay can be fabricated chair side
• Eliminates asepsis
• Since its computer assisted crowns of correct dimensions can be obtained
• Glazing is not required : can be polished
• Less abrasion of tooth structure : homogenous material
All Ceramics – Dr. Nithin Mathew 128
DISADVANTAGES : Machinable Ceramics
CELAY SYSTEM
COPYING SIDE
• Various size probes represent
size of diff milling burs is run
• Switzerland in 1992
over surface of pattern
• High precision manually operated
• Key duplication
MILLING SIDE
• Advantage : Recreation of all surfaces. • At same time matched rotary
instru-mills same shape out of
restorative block
SONO EROSION:
• The ceramic blank is surrounded by an abrasive suspension of hard particles, such as boron
carbide, which are accelerated by ultrasonics, and thus erode the restoration out of the
ceramic blank.
SPARK EROSION:
• Metal removal process using a series of sparks to erode material from a workpiece in a liquid
medium under carefully controlled conditions.
• Fabrication
Finished
Trimming ceramic core Veneering
framework
All Ceramics – Dr. Nithin Mathew 133
BONDING OF PORCELAINS
RESIN–CERAMIC BONDING
• Function of the silane primer between porcelain and the composite resin plays an important
role.
• Etching of ceramic surface with 7.5 to 10% hydrofluoric acid for 2-10mins and then followed
by silanization increased the bond strength to porcelain (Peremuter and Montagonon, 1981)
2. Mechanical interlocking:
• Due to surface irregularity of the alloy
• Air abrasion with aluminium oxide particles
1. PORCELAIN REPAIR :
• Fracture is totally in porcelain
• Simplest repair
• Surface roughening by using diamond burs, air abrasion and acid etching
with 9.5% HF acid
• More complicated
• If remaining porcelain:
• Most difficult
• 2 methods :
• Veneering exposed metal surface with direct bonding of shade matched composite
after preparation of exposed metal surface for bonding.
• Corrosion products
• All ceramic restoration transmits certain percentage of incident light to ceramic core & post .
• Color of final restoration will be derived from an internal shade
• Depth of translucency in cervical root area
• Biocompatible
MATERIALS USED
• In–ceram
• Dense – sintered alumina ceramic
• Zirconium oxide ceramics
• Bioactive Ceramics : High density Alumina, TriCalcium Phosphate, High Alumina polymer
composite
• Inert Ceramics : Alumina, Zirconium Oxide
Composition
• Glass inserts
• Lithium – alumino-silicate glass (heat treated & silanated)
eg: Beta –Quartz Glass –ceramic inserts
• Ceramics:
• Abrasion resistance
• High stability
• Esthetics
• Composites
• Ease of final adjustments
• Excellent polishability
• Bonding with luting cement
• Possibility of repair
All Ceramics – Dr. Nithin Mathew 143
ZIRCONIA IMPLANTS
• An increase of the crystalline content as seen in the pressable materials and the fully sintered
zirconia generally corresponds to an improvement of the mechanical properties.
• Vita Inceram crowns exhibited significantly higher fracture strength than conventional all-
ceramic crowns.
• The fracture strength of monolithic high translucent zirconia crown is considerably higher
than that of porcelain-veneered zirconia crown cores, porcelain-veneered high translucent
zirconia crown cores and monolithic lithium disilicate crowns.
• Lithium Disilicate glass-ceramic restorations had higher fracture resistances than leucite
reinforced glass-ceramic restorations.
• Observations regarding zirconia-based all ceramic restorations compared with PFM restorations:
• Long-term color stability probably will be the same as that with PFM restorations
• Margins of the restorations have a more acceptable appearance than those of PFM.
• Strength and service record of PFM restorations and zirconia based restorations in three-unit
prostheses is similar.
1. Substrate
2. Flexure risk assessment
3. Excessive shear and tensile stress risk assessment
4. Bond/seal maintenance risk assessment
• Is it enamel?
• How much of the bonded surface will be enamel?
• How much enamel is on the tooth?
• How much of the bonded surface will be dentine?
• What type of dentine will the restoration be bonded to? Is it a restorative material (e.g.
composite, alloy)?
• Each tooth and existing restorations are evaluated for signs of past overt tooth flexure.
• Signs
• Recession
• Abfraction lesions
• Low risk
• Low wear; minimal to no fractures or lesions
• Patient’s oral condition is reasonably healthy
• Medium risk
• Signs of occlusal trauma
• Mild to moderate gingival recession along with inflammation
• Bonding mostly to enamel is still possible
• There are no excessive fractures
• High risk
• Evidence of occlusal trauma from parafunction;
• More than 50 % of dentine exposure exists
• Significant loss of enamel due to wear of 50 % or more
• Porcelain must be built up by more than 2 mm.
• All types of ceramics (especially porcelains) are weak in tensile and shear stresses.
• The substructure should reinforce the veneering porcelain by utilising the reinforced-
porcelain system technique
• If the bond and seal cannot be maintained, then high-strength ceramics or metal ceramics are
the most suitable, since these materials can be placed using conventional cementation
techniques.
• Dental ceramic technology is one of the fastest growing areas of dental material research and
development. The past decades have seen the development of several new groups of ceramics.
• Each system has its own merits, but may also have shortcomings.
• Combinations of materials and techniques are beginning to emerge which aim to exploit the
best features of each.
• Glass-ceramic and glass-infiltrated alumina blocks for CAD-CAM restoration production are
examples of these.
• The diversity and sophistication of the CAD-CAM systems may prove to be influential in the
future.
All Ceramics – Dr. Nithin Mathew 164
REFERENCES