Effects of material and piston diameter on the fatigue behavior, failure mode, and stress distribution of feldspathic ceramic simplified restorations.

This study evaluated the influence of the piston material (glass fiber-reinforced epoxy resin or stainless steel) and the piston tip diameter (6 or 40 mm) on the fatigue mechanical behavior, failure mode, and stress distribution of feldspathic ceramic simplified restorations. Pistons were machined in glass fiber-reinforced epoxy resin (ER) and in stainless steel (SS), with active tips simulating the curvature radius of 6- or 40-mm diameter spheres. A total of sixty (N= 60) feldspathic ceramic discs (Ø= 10 mm; thickness= 1.0 mm) were adhesively luted onto supporting substrate discs (Ø= 10 mm; thickness= 2.5 mm) and allocated into 4 groups (n= 15) according to the piston used for fatigue testing: ER_6, ER_40, SS_6, SS_40. Afterwards, the specimens were submitted to the cyclic fatigue test (20 Hz frequency; initial load= 100 N; step= 50 N; 10,000 cycles/step, upon specimen failure detection). The collected data were analyzed by two-way ANOVA (α= 0.05) to verify differences by considering 'piston material' and 'piston diameter' as factors, and their association. In addition, a survival analysis (Kaplan Meier with Mantel-Cox log-rank post-hoc tests) was conducted (α= 0.05). Fractographic and finite element (FEA) analyzes were also performed. 'Piston material' (p= 0.040, F= 4.43) and 'piston diameter' (p < 0.000, F= 563.21) had a significant influence on the fatigue failure load (FFL) and the number of cycles for failure (CFF) values. Feldspathic restorations showed higher FFL and CFF (p < 0.05) when tested with a 40 mm diameter piston compared to a 6 mm diameter piston (ER_40 and SS_40 > ER_6 > SS_6). In relation to the piston material, ER and SS pistons with 40 mm diameter promoted similar fatigue performance (ER_40: 946.67 N/179,333 cycles = SS_40: 936.67 N/177,333 cycles), while 6 mm diameter groups presented different fatigue performance (ER_6: 440 N; 78,000 cycles > SS_6: 353.3 N; 60,667 cycles). Hertzian cone crack failures were only observed in the groups tested with 6 mm pistons, regardless of piston material. Higher stress concentration on the ceramic surface was observed when using 6 mm diameter pistons, whereas the SS_6 group showed a slight increase in stress concentration in comparison to the ER_6 group. The piston diameter showed an influence on the fatigue behavior, failure mode, and stress distribution of feldspathic ceramic simplified restorations. However, the influence of piston material is only observed when 6 mm diameter pistons are used. The 40 mm diameter pistons led to radial crack, being more appropriate for fatigue test of simplified feldspathic ceramic restorations with a thickness ≤ 1 mm. Whilst the 6 mm diameter pistons should be avoided, once tend to induce Hertzian cone crack failures and to underestimate fatigue performance.