Thermal stress behavior of monolithic zirconia crowns with different thicknesses.

Purpose: This study was aimed at investigating the thermal stresses in monolithic zirconia crowns (MZC) of various thicknesses and elucidating their thermal behavior under cooling or heating changes in the oral cavity. Additionally, the clinical availability and potential issues of MZC were examined by comparing them with other crown materials.

Methods: Finite element models comprising MZC (0.5-, 1.0-, and 1.5-mm thick), cement layers, and abutment teeth were subjected to thermal changes from 37 to 5 °C or 60 °C. Using a thermal distribution at 5 s, the thermal stress was calculated and compared with those of gold alloy and resin composite crowns. The loads corresponding to the thermal stresses were also estimated by comparing them with the stresses induced by vertical loading on the occlusal surface.

Results: Tensile stress occurred primarily in the crowns and cement during cooling, whereas compressive stress was generated during heating. Thermal stresses increased from 16.0 to 27.2 MPa with decreasing crown thickness from 1.5 to 0.5 mm and varied with different materials. Although the MZC exhibited the highest thermal stress, the estimated load (200 N) corresponding to the thermal stress was smaller than that of the resin composite (1280 N).

Conclusions: Thinner crowns exhibited higher thermal stress, suggesting an increased risk of failure owing to thermal changes. Despite the higher thermal stress in thinner MZC, the stresses were below the fatigue strength of the material, indicating sufficient resistance to thermal changes in the oral cavity.