Purpose: To explore the effect of in situ synthesized particulates on a zirconia surface on the bonding properties between zirconia and porcelain.

Materials and methods: Presintered yttrium-stabilized tetragonal zirconia (Y-TZP) was cut into slices and bars and polished with 1,200-grit silicon carbide abrasive paper. Samples were randomly divided into six groups (C, I₁, I₃, I₅, I₇, and I₉) according to immersion time in hydrofluoric acid solution (0, 10, 30, 50, 70, and 90 seconds, respectively). Then, the samples were placed in calcium chloride solution for 90 seconds and dipped in sodium hydroxide solution at 80°C for 2 hours. After sintering, the surface topography and roughness were examined. After the porcelain was fired, the bonding interface was observed, and cross-sectional microhardness was measured. The shear bond strength of the zirconia to porcelain was evaluated, and failure modes were classified. A 3-point bending test was applied to confirm the effects of the treatment on the mechanical properties. The above data were statistically analyzed.

Results: Polycrystalline particulates were synthesized on the zirconia surface. The surface roughness values increased as the immersion time of the samples in hydrofluoric acid increased. The cross-sectional microhardness decreased gradually in the experimental groups. Group I₇ showed an elevated bond strength (27.02 ± 2.44 MPa). Mainly mixed failure mode was obtained in the experimental groups. The Weibull characteristic strength for the experimental groups was higher than that of group C. The flexural strengths were not significantly different among the groups.

Conclusions: In situ synthesized polycrystalline particulates on zirconia could effectively improve the bonding between zirconia ceramics and porcelain without significantly decreasing the mechanical properties.