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<p>The tribological performance of dental crown materials plays a critical role in their long-term clinical durability. Although 3&#xa0;mol% yttria-stabilized zirconia (3YSZ) exhibits excellent mechanical strength, its high hardness can accelerate wear of opposing dentition. This study investigates monolithic 3YSZ and two zirconia-based hybrid composites, C5 (50 vol% 3YSZ–48 vol% CaSiO₃–2 vol% Ag) and C9 (29 vol% 3YSZ–68 vol% CaSiO₃–3 vol% Ag), through an integrated framework combining full-factorial tribological experimentation, statistical optimization, surface characterization, and Archard-based finite element modelling to establish composition-dependent wear mechanisms and predictive tribological performance under loads of 20–60&#xa0;N and sliding speeds of 200–600&#xa0;rpm. Dry sliding behaviour was evaluated through pin-on-disc testing to determine coefficient of friction (COF), specific wear rate (SWR), and post-wear surface roughness. The C5 composite exhibited the lowest friction (COF: 0.10–0.15) and minimum surface roughness (Ra = 0.0235&#xa0;μm), whereas the C9 composite demonstrated the lowest wear rate (0.139 × 10⁻¹⁴ m³/(N·m) and highest Taguchi signal-to-noise ratio (17.14) at 60&#xa0;N and 400&#xa0;rpm. Three-factor factorial ANOVA confirmed material composition as the dominant factor influencing tribological performance (<i>p</i> &lt; 0.05), with a significant material–load interaction. Surface analyses using AFM and SEM revealed a transition from brittle fracture in monolithic 3YSZ to stable tribo-layer–controlled mild wear in hybrid composites. Finite element simulations incorporating Archard’s wear model showed strong agreement with experimental results (88.89% within Bland–Altman limits), validating predictive reliability. Overall, hybrid reinforcement with calcium silicate and silver significantly improved the tribological stability of zirconia. The findings demonstrate distinct optimization regimes, with C5 friction-optimized and C9 wear-optimized, providing an evidence-based framework for application-specific dental material selection.</p>

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Experimental and finite element analysis of dry sliding wear in zirconia–calcium silicate–silver composite

  • 期刊论文

  • 发表日期：

    2026年7月27日

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  • R. Manimaran,
  • Sumit Pramanik,
  • Sandipan Roy

摘要

The tribological performance of dental crown materials plays a critical role in their long-term clinical durability. Although 3 mol% yttria-stabilized zirconia (3YSZ) exhibits excellent mechanical strength, its high hardness can accelerate wear of opposing dentition. This study investigates monolithic 3YSZ and two zirconia-based hybrid composites, C5 (50 vol% 3YSZ–48 vol% CaSiO₃–2 vol% Ag) and C9 (29 vol% 3YSZ–68 vol% CaSiO₃–3 vol% Ag), through an integrated framework combining full-factorial tribological experimentation, statistical optimization, surface characterization, and Archard-based finite element modelling to establish composition-dependent wear mechanisms and predictive tribological performance under loads of 20–60 N and sliding speeds of 200–600 rpm. Dry sliding behaviour was evaluated through pin-on-disc testing to determine coefficient of friction (COF), specific wear rate (SWR), and post-wear surface roughness. The C5 composite exhibited the lowest friction (COF: 0.10–0.15) and minimum surface roughness (Ra = 0.0235 μm), whereas the C9 composite demonstrated the lowest wear rate (0.139 × 10⁻¹⁴ m³/(N·m) and highest Taguchi signal-to-noise ratio (17.14) at 60 N and 400 rpm. Three-factor factorial ANOVA confirmed material composition as the dominant factor influencing tribological performance (p < 0.05), with a significant material–load interaction. Surface analyses using AFM and SEM revealed a transition from brittle fracture in monolithic 3YSZ to stable tribo-layer–controlled mild wear in hybrid composites. Finite element simulations incorporating Archard’s wear model showed strong agreement with experimental results (88.89% within Bland–Altman limits), validating predictive reliability. Overall, hybrid reinforcement with calcium silicate and silver significantly improved the tribological stability of zirconia. The findings demonstrate distinct optimization regimes, with C5 friction-optimized and C9 wear-optimized, providing an evidence-based framework for application-specific dental material selection.