Methods: The thermo-elastic basis for residual stresses and the influence of cooling rate and specimen size will be considered. Zirconia and alumina plates 10 by 20 mm and 0.6 mm thick veneered with appropriate porcelains (e.max Ceram, IvoclarVivadent) and (VM7, Vita Zahnfabrik) of various thicknesses (0.5 to 2.5 mm) and subjected to different cooling rates were investigated. Vickers indentations from 5 to 30 N were placed on the surface of veneering porcelain and the size of the cracks measured.
Results: Length of radial cracks were smaller for rapidly cooled specimens for the porcelain on both alumina and zirconia copings indicative of surface compressive residual stresses. Only for the porcelain fused to the rapidly cooled zirconia coping samples was unstable cracking within the veneering porcelain observed.
Conclusion: The results are interpreted in terms of the thermo-elastic analysis developed. Suggestions to improve processing of zirconia based restorations by technicians and adjustment procedures by clinicians to minimise chipping are also considered.