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Effect of Metal Design on Marginal Distortion of Metal-Ceramic Crowns

Article in Journal of Dental Research · December 1984

DOI: 10.1177/00220345840630111501 · Source: PubMed

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 Journal of Dental Research
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Effect of Metal Design on Marginal Distortion of Metal-Ceramic Crowns

P.H. DeHoff and K.J. Anusavice
J DENT RES 1984 63: 1327
DOI: 10.1177/00220345840630111501

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Effect of Metal Design on Marginal
Distortion of Metal-Ceramic Crowns
P.H. DeHOFFl* and K.J. ANUSAVICE2
1Mechanical Engineering and Engineering Science Department, University ofNorth Carolina at Charlotte, North Carolina 28223; and 2Depart-
ment of Dental Biomaterials, College of Dentistry, University of Florida, Gainesville, Florida 32610
An analysis of residual stress and marginal distortion due to thermal shoulder-bevel preparations. In contrast with the results of
contraction mismatch between metal and ceramic is presented for Ando et al (1972), the greatest marginal opening changes
metal-ceraimic crowns. Using dilatometric data, finite element stress occurred during those stages when porcelain was fired to
analyses were performed on pre-molar crowns designed with cham- the copings. All four specimen designs exhibited progres-
fer-knife edge, chamfer with collar, shoulder with collar, and sively greater marginal gap changes through the first firing
shoulder-bevel with collar geometries and a maxillary central incisor
crown with a chamfer-knife edge geometry. Calculations were made of body porcelain.
using combinations of a Ni-Cr alloy or a Au-Pd alloy with each of Iwashita et al (1977) studied the effect of full vs. partial
three porcelain products. Calculated marginal distortions due to porcelain coverage and variable metal thickness on the mar-
crown design and metal-porcelain thermal contraction incompati- ginal discrepancy. Gold alloy porcelain crowns were used in
bility were found to be well below experimental values found in the this study. It was concluded that a larger marginal discrep-
literature. For the cases studied, the calculated marginal distortions ancy and a corresponding poorer fit resulted for specimens
due to metal-porcelain thermal contraction mismatch depend pri- with full porcelain coverage. Although the oxidation pro-
marily on the metal-porcelain combination and are insensitive to the cedure contributed to the marginal discrepancy, the effect
coping design. However, this study excluded copings which have
been extensively ground to thicknesses of 0.1 mm or less, and such of the thermal contraction differential between metal and
copings may be more susceptible to localized or generalized dis- porcelain was found to be significant.
tortion. Kulmer et al. (1978) developed a technique to minimize
dimensional changes that occurred routinely in gold alloy-
J Dent Res63(11):1327-1331, November, 1984 ceramic crowns during oxidation. The greatest dimensional
change of any crown following the heat treatment pro-
Introduction. cedure of this technique was 19 pm. No additional changes
were observed after a subsequent free-oxidation process.
Studies of bimaterial strip flexure and opening or closure This study showed that the controlled relaxation of solidi-
of a split metal ring during firing have provided ample evi- fication stress may greatly reduce subsequent framework
dence that distortion of metal copings or frameworks may distortion.
result from relaxation of solidification stresses or as a result Faucher and Nichols (1981) introduced a technique for
of thermal contraction incompatibility. However, a contro- monitoring marginal changes which occurred during a series
versy exists over the extent to which porcelain-metal in- of firing procedures. The external surface of the margin was
compatibility may cause localized marginal distortion of traced and profiled in two dimensions. Profiles were fabri-
metal-ceramic crowns or bridges. Complicating the analysis cated for maxillary central incisor crowns with chamfer,
of incompatibility distortion of long-span bridges is the shoulder, and shoulder-bevel preparations. Except for a
potential for alloy creep or sag during the porcelain firing metal gingival collar, each crown received full porcelain
cycles. coverage. For each crown, there was an increase in the
Ando et al (1972) reported that the marginal dis- mesiodistal dimensions and a decrease in the faciolingual
crepancy change of open-ended castings (with and without dimensions. Although most of the distortion occurred
a partial porcelain veneer) which were placed on a tapered during the oxidation cycle, additional dimensional changes
(1:10) die was greatest after the oxidation ("de-gassing") occurred during subsequent firing procedures. Specimens
treatment. The term "oxidation" will henceforth be used in with a chamfer preparation exhibited significantly greater
lieu of the term "de-gassing", since the primary purpose of (p < 0.01) distortion than did the shoulder or shoulder-
this procedure is to provide an oxide layer which will en- bevel designs. No significant difference was detected
hance bonding to dental porcelain. Positive gap changes of between shoulder and shoulder-bevel specimens.
about 100 pm and 150 Mm were observed for two different Buchanan et at (1981) reported greater marginal dis-
alloys using a shoulder preparation. Three additional alloys tortion of a base metal alloy as compared with a Au-Pt-Pd
resulted in negative dimensional changes ranging from 100 alloy when fired with porcelain. The metal oxidation pro-
pm to 150 pm. No significant further gap changes occurred cedure resulted in a marginal opening change of about 70
as a result of porcelain firing procedures or a final harden- pm for the base metal and 7 pm for the gold base alloy.
ing heat treatment at 5500C for ten min. Subsequent simulated opaque and body porcelain firing
Shillingburg et al (1973) published the results of mar- procedures produced little additional gap changes compared
ginal gap changes that resulted during each firing cycle for with those observed as a result of the oxidation cycle. The
four different coping designs. Specimens of a Au-Pd-Ag larger distortion for the base metal alloy was attributed to
alloy and a porcelain product were fabricated for adapta- the formation of a layer of oxide on the internal surfaces of
tion to dies with chamfer, chamfer-bevel, shoulder, and these copings.
Based on these studies, it appears that stress relaxation
which occurs during the oxidation cycle may be a major
Received for publication April 24, 1984 cause of marginal or generalized distortion of alloy frame-
Accepted for publication August 14, 1984 works. This suggests that the release of residual stresses
This study was supported by NIDR Grant DE06672, NIDR
RCDA DEOO1 17, and NSF Grant SPI 7926904. resulting from the casting process accounts for a major part
*Present address: Department of Dental Biomaterials, College of of the observed distortion. The popular belief at the present
Dentistry, JHMHC, University of Florida, Gainesville, FL 32610 time is that the thermal contraction differential between
1327
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1328 DeHOFF & ANUSA VICE J Dent Res November 1984

an alloy and its porcelain veneer is the principal cause of 8.0

crown distortion.
Little research has been performed to resolve this con-
troversy. The objective of this study was to evaluate the
effect of coping design on the distribution of residual
stresses and metal displacements in metal-ceramic crowns
due to thermal contraction differences. 6.0
Materials and methods.
Residual stress and marginal distortions were calculated
using the SAAS3 finite element computer code which was E
developed by Crose and Jones (1971). This computer code E 4 .0
is based on linear elastic behavior and can be used for axi- -

symmetric and plane stress (two-dimensional) cases. The

program contains triangular and quadrilateral elements with CD
assumed linear displacement fields. Pre-molar crowns with LI
full porcelain coverage were modeled as axisymmetric
figures, while a maxillary central incisor with full porce- 2.0
lain coverage was modeled as a two-dimensional figure.
The central incisor crown, which has a chamfer-knife edge
geometry, is similar to that reported by Farah and Craig
(1975). Coefficients of thermal contraction and glass transi-
tion temperatures for the materials were obtained from
the study of Fairhurst et al. (1980).
Calculations were made using combinations of either a 0 2.0 4.0 6 .0
Ni-Cr alloyl or a Au-Pd alloy2 with each of three porcelain
products.3-5 For each of the pre-molar metal-porcelain RADIUS (mm)
combinations, finite element analyses were performed on Fig. 1 Finite element model of the shoulder-bevel with collar
crowns with the following gingival configurations: chamfer- geometry.
knife edge margin, chamfer with collar, shoulder with
collar, and shoulder-bevel with collar.
A typical finite element layout used in the analysis of PA
121
the shoulder-bevel with collar configuration is shown in Au-Pd ALLOY
Fig. 1. Because the linear displacement model yields some- PORCELAIN B ---
what stiffer elements than is desirable, partial models of 0 - PORCELAIN C
finer mesh were analyzed to determine residual stress a-
1: -_ --PORCELAIN V
levels in critical locations. The partial models did not result
in significantly different stress values, and those results will Co0
.0
not be presented. No attempt was made to model the oxi- w

dation layer, and perfect bonding was assumed to exist TENSILE

cn 4i0 - -
cn
-

between metal and opaque porcelain and between opaque

porcelain and body porcelain. COMPRESSIVE
0
Results. co Si
w
F
The residual stress state which develops at room temper- 0
M
ature is due primarily to the thermal contraction mismatch BODY
between metal, opaque porcelain, and body porcelain. L I . I . -
. . .

Calculations are based on the assumption of a stress-free

120
0 1 .0 2.0
state in the metal above the glass transition tempera- DISTANCE ALONG EF(mmr)
ture (Tg) of the porcelain. Since the Tg values differ for Fig. 2 - Calculated tangential residual stress distribution in
body and opaque porcelains, the lower Tg value was se- systems O-B, O-C, and O-V for the chamfer-knife edge design.
lected as the zero stress state in each case. The stress which
develops at the higher Tg value is assumed to have a negligi-
ble effect on the room temperature residual stresses. studied. Shown in Figs. 6 and 7 are similar results for the
Although calculated stresses are available for each ele- central incisor design. These stresses are essentially tangen-
ment in the model, only typical results are presented. tial stresses which occur within a typical plane through the
Shown in Figs. 2-5 are residual stress distributions within longitudinal axis. Stresses are shown along section EF in
the pre-molar crown for the metal-porcelain combinations Figs. 2, 4, and 6 for the chamfer-knife edge, shoulder-
bevel with collar, and central incisor designs, respectively.
The shoulder with collar and chamfer with collar cases are
not shown, because the stress distributions are essentially
lJelbon(J), J.F. Jelenko & Co., Armonk, NY 10504 the same as for the shoulder-bevel with collar design.
20lympia(O), J.F. Jelenko & Co., Armonk, NY 10504 In Fig. 3 it can be observed that, for the J-C System, a
3Biobond(B), Dentsply International, York, PA 17404
4Ceramco(C), Ceramco, Inc., East Windsor, NJ 08520 maximum stress in metal of 196 MPa occurs in the crown
5Vita(V), Unitek, Monrovia, CA 91016 design with a chamfer-knife edge marginal configuration.

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Vol. 63 No. I11 MARGINAL DISTORTION OFMETAL-CERAMIC CROWNS 1329
201 ou

1510.
Ni-Cr ALLOY Ni-Cr ALLOY
- - - PORCELAIN B - - - PORCELAIN 8
u PORCELAIN C 1010 PORCELAIN C
1010 :.- - - PORCELAIN V u - - -PORCELA IN V
o- _tifnMM 0 T%C

CD)Lii TENSILE C,)

C,)
5
LiJ
-
va
0
_____ TENSILE
cn COMPRESSIVE
-
uumrmtbblvt
LL ...... .

cz
Id
0 I- 6-J 50
C)
_
LiJ 100
M OP BODY
-
c UlIA
'9
vJvI , . .
OP BODY
1 .0 2.0 150 L a I . I.
DISTANCE ALONG EF(mm) 1 .0 2.0
Fig. 3- Calculated tangential residual stress distribution in sys- DISTANCE ALONG EF(mm)
tems J-B, J-C, and J-V for the chamfer-knife edge design.
Fig. 5 - Calculated tangential residual stress distribution in
systems J-B, J-C, and J-V for the shoulder-bevel with collar design.
101 0I I I I

Au-Pd ALLOY
---PORCELAIN B 50
PORCELAIN C Au-Pd ALLOY
U
Q-& -- - PORCELAIN B
a. 510 ---PORCELAIN V
- PORCELAIN C
25 - -PORCELAIN V
cn
0-
CL)
Li
co TENSILE
H Li
0o TENSILE
0 --
0 COMPRESSIVE co 0 .

" 51 KM ;
tOP BODY COMPRESSIVE
cD 25
Li.
CL

M- OP BODY
100L- I .0 2.0 50- I-0.5 1 .5
DISTANCE ALONG EF(mm) DISTANCE ALONG EF(mm)
Fig. 4 - Calculated tangential residual stress distribution in sys-
tems O-B, 0-C, and O-V for the shoulder-bevel with collar design. Fig. 6 - Calculated tangential residual stress distribution in
systems O-B, 0-C, and O-V for the central incisor design.
Shown in Figs. 2 and 3 are fairly high tensile stresses (65-68
MPa) that develop in the opaque porcelain layer for the Although only typical stress results are shown in Figs.
O-V and J-V combinations, respectively. On the other 2-7, a review of the stress states in all elements in each
hand, relatively low tensile stresses develop at the surface of crown design indicates that the highest stress in the metal
the body porcelain layer for the O-B and J-B combinations. coping occurs for the J-C system for the chamfer-knife
Shown in Figs. 4 and 5 are the stress distributions for the edge design. However, even this stress state was well below
shoulder-bevel with collar design in which similar trends are the yield stress of 500 MPa for this Ni-Cr alloy. On the
observed with a surface tensile stress of 21 MPa occurring other hand, calculated stresses in the opaque layer for por-
in the O-B combination. celain V in combination with either alloy were near failure
The results for the central incisor crown are presented in levels for all designs, assuming a tensile strength of 70
Figs. 6 and 7. Moderately high tensile stresses develop MPa for porcelain.
in opaque porcelain for the O-V and J-V systems. In The highest tensile stress for body porcelain developed
addition, for both the O-B system and the J-B system, at the opaque-body interface for the O-B and J-B systems
the stress distribution changes from a tensile state at the for all designs. While these stresses were well below the
opaque-body interface to a compressive state at the body tensile strength of porcelain, the presence of any residual
porcelain surface. On the other hand, all other combina- tensile stress would make these systems more susceptible
tions vary from compressive stress at the opaque-body to failure when subjected to intra-oral occlusal forces.
interface to tensile stress at the body porcelain surface. At Listed in the Table are the radial and vertical displace-
any rate, the surface stress levels do not exceed 10 MPa for ments of the marginal area of each crown. Displacement
any combination. results are shown for the pre-molar crown modeled axi-

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1330 DeHOFF & ANUSA VICE J Dent Res November 1 984

symmetrically, the pre-molar crown modeled in a two- that some minor local marginal distortion occurred, al-
dimensional configuration for the O-B combination, and though the actual magnitudes are quite small.
the central incisor. Positive values are taken as those dis- The deformed geometry was calculated by taking the
placements which cause the crown to expand in the radial
direction and contract in the vertical direction.
For the axisymmetric model, the maximum positive
radial distortion occurred in the Au-Pd coping for the
chamfer with collar design in combination with porcelain B.
The maximum positive vertical distortion occurred in the
Au-Pd metal coping for the chamfer-knife edge design with
porcelain B. The two-dimensional model of the O-B pre-
molar crown is much more flexible than the axisymmetric
model and resulted in larger radial and vertical distortions
for all metal designs. The central incisor is also a two-
dimensional model and therefore yielded larger distortions
for all metal-porcelain combinations.
Shown in Fig. 8 is the deformed outline (shaded area)
superimposed on the un-deformed configuration for the J-B
system and the chamfer with collar design. The displace-
ments have been magnified by 100 times in order to high-
light the marginal distortion. The deformed plot indicates

Ni-Cr ALLOY
/ - --PORCELAIN B
0
PORCELAIN C
a.. 25 -. - PORCELAIN V

LUJ
___TENSILE
-
COMPRESSIVE .-
''--

P-J
25
Co
LLJ
Q:
.M i- BODY
AR- >
0.5 1 .5
D ISTANCE ALONG EF (mm ) Fig. 8 - Deformed geometry (shaded area) superimposed on the
Fig. 7 - Calculated tangential residual stress distribution in un-deformed geometry for the J-B system and chamfer with collar
systems J-B, J-C, and J-V for the central incisor design. design. The displacements are magnified by 100 times.

TABLE
MARGINAL DISTORTIONS IN RADIAL AND VERTICAL DIRECTIONS (Jim)

Metal- Chamfer- Chamfer Shoulder Shoulder-Bevel Central

Porcelain Knife Edget With Collart With Collart With Collart Incisor*
System* AR§ AZ§ AR AZ AR AZ AR AZ AR AZ
J-B +1.2 +2.8 +1.1 +1.4 +0.8 +1.4 +1.0 +1.4 +9.9 +3.4
J-C +1.8 -4.9 -1.2 -4.6 +0.3 -4.4 -1.1 -4.4 -9.6 -6.0
J-V -0.6 -3.6 -1.2 -2.4 -0.8 -2.3 -1.1 -2.2 -10.8 -4.3
O-B +0.1 +5.3 +1.9 +4.0 +1.1 +3.8 +1.7 +3.8 +15.4 +6.6
O-C +1.2 -2.5 +0.5 -2.5 0.0 -2.4 -0.4 -2.5 -4.3 -3.2
O-V -1.7 -0.8 -0.8 +0.2 -0.8 +0.1 -0.7 -0.2 6.2 -0.8
O-B +15.4 +11.9 +20.0 +11.5 +17.4 +11.2 +19.9 +11.2 +15.4 +6.1
*Jelbon (J) and Olympia (0), J.F. Jelenko & Co., Armonk, NY 10504
*Biobond (B), Dentsply International, York, PA 17404
*Ceramco (C), Ceramco, Inc., East Windsor, NJ 08520
*Vita (V), Unitek, Monrovia, CA 91016
tAnalyzed with an Axisymmetric Model
t-Analyzed with a Plane Stress Model
§ Positive displacements are taken as those which cause the crown to expand in the radial direction (AR) and contract in the vertical direc-
tion (AZ).

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Vol. 63 No. I11 MARGINAL DISTORTION QFMETAL-CERAMIC CROWNS 1331

difference in displacements between a free contraction of able to obtain a measure of the residual stress in the porce-
the metal coping and the contraction of the metal-ceramic lain. While the accuracy of this procedure is questionable,
system. In all cases, the reference temperature was taken as the porcelain surface stress levels of 5 to 10 MPa reported
the glass transition temperature of the porcelain at which by Derand are in rough agreement with those found in this
the coping was assumed to be undistorted and at a zero study for the O-B cases (axisymmetric model).
stress state. Another result of this study can be observed from the
Table. For the cases studied, the calculated marginal dis-
tortions due to metal-porcelain thermal contraction mis-
Discussion. match depend primarily on the metal-porcelain combina-
tion and very little on coping design. This is true even for
In interpreting the results of this study, a number of the chamfer-knife edge case, in which the metal is thinned
factors should be considered. This finite element stress to 0.1 mm in the marginal region, and a maximum porce-
analysis is based on an elastic model which does not take lain thickness of 2 mm is assumed. However, it is possible
into account the visco-elastic behavior of the porcelain near that copings which have been extensively ground through-
the softening temperature, nor does the element layout out (0.1 mm or less) may be more susceptible to localized
exactly duplicate the true geometry of metal-ceramic or generalized distortion.
crowns. Moreover, there is little agreement in the literature
concerning what values should be taken for glass transition REFERENCES
temperatures or for the coefficients of thermal contraction
for the porcelains. Constant values were taken for the ANDO, N.; NAKAMURA, K.; NAMIKI, T.; SUGATA, T.; SUZUKI,
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near the softening temperature. The Effect of Repeated Firings and Strength on Marginal Distor-
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MOTO, K.; HARADA, H.; UOCHI, T.; and HATA, Y. (1977):
the oxidation cycle. The findings presented here tend to Studies on Dimensional Accuracy of Porcelain Fused to Precious
agree with these studies. However, truly meaningful experi- Metal Crown. The Influence of the Porcelain to the Metal Coping
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crowns are difficult to obtain because of measurement KASE, H.R.; CASE, E.; and TESK, J.A. (1983): Elastic Constants
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