Eigenstrain boundary layer modelling of the yttria-partially stabilised zirconia–porcelain interface in dental prostheses

The exceptional strength and appealing aesthetics of porcelain veneered yttria partially stabilised zirconia (YPSZ) dental prostheses, has led to the widespread adoption of these materials. However, near-interface chipping of the porcelain remains the primary failure mode. Advanced experimental techniques have recently revealed significant variations in residual stress and YPSZ phase distribution at the YPSZ–porcelain interface. Therefore, in order to improve existing understanding and effectively optimise the production of these devices, an enhanced model of the YPSZ coping that includes these newly discovered phenomena is presented in this study. Macroscale stresses are shown to arise through the uneven temperatures within the coping during the sintering process and the coefficient of thermal expansion mismatch with the porcelain during veneering. In contrast, microscale stresses are driven by the YPSZ phase transformation and the associated volumetric expansion. The eigenstrain approach proposed here was found to demonstrate a good match between the phase variation determined experimentally, and the corresponding residual stress distribution showed an effective comparison with the empirical measurements. The proposed technique is a straightforward but powerful method for simulating this dominant mechanical behaviour, with significant potential to combine the resulting expressions into existing models. These enhanced simulations are the only viable approach for the precise, reliable and systematic optimisation of prosthesis production parameters that are needed to significantly reduce prosthesis failure rates.