Objective: Due to its favorable properties, the high-performance polymer polyetheretherketone (PEEK) is used as a metal-free alternative for the fabrication of denture frameworks. For dental applications, PEEK is available in different colors, such as red or white, by compounding with different fillers. In order to permanently bond such different dental PEEK types together in a denture framework, ultrasonic welding could be a viable process. Therefore, the aim of this study was to determine the optimum processing welding parameters for welding different dental PEEK grades in terms of maximum weld strength.
Methods: Rectangular plates from three PEEK compounds were prepared according to the dimensions of a removable partial denture (RPD) of PEEK. These were combined in a way that four groups resulted, whereas the combination of pure PEEK served as control. In each group, 5 samples were ultrasonically welded at one of four welding energies using a microprocessor-controlled ultrasonic welder, where the welder was activated only once. Afterwards, the samples were subjected to tensile tests to evaluate the shear bond strength (SBS) of the joint.
Results: Increasing the welding energy resulted in an increase in the welding time. Accordingly, the increase in the welding energy increased the surface deformation for all tested samples. The shear bond strengths ranged from 4.8 ± 0.68 MPa for samples welded with 50 Ws to 16.37 ± 1.69 MPa for samples welded with 90 Ws. Excessive weld energy of 130 Ws led to a significant decrease of SBS due to a severe indentation and perforation induced by the sonotrode.
Significance: The SBS and topography of the welded samples were systematically studied and the optimal welding parameters were determined. This could serve as a reference and instruction for clinical applications.
Keywords: PEEK; Removable partial denture; Shear bond strength; Ultrasonic welding.
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