High-Temperature Hydrofluoric Acid Etching Increases the Debonding Resistance of Zirconia Copings Cemented to Titanium Bases: An In Vitro Study

This study compared three internal surface treatments of zirconia copings-silane alone (control), airborne-particle abrasion followed by silane, and high-temperature hydrofluoric acid etching followed by silane-regarding initial pull-out retention strength, retention after thermocycling, failure mode assessed by scanning electron microscopy (SEM), and surface wettability. Sixty-three monolithic zirconia copings were allocated to three groups (n = 21) according to surface treatment and cemented to titanium bases with a self-adhesive resin cement. Initial pull-out tests were performed. A subset (n = 10 per group) underwent thermocycling followed by repeat testing. Failure modes were analysed by SEM, and wettability was measured using the sessile drop method. Surface roughness and crystalline phase were additionally characterized by white-light interferometry and X-ray diffraction (XRD), respectively. High-temperature acid etching produced significantly higher initial pull-out forces than airborne-particle abrasion and silane alone, with mean values 125% higher than control and 42.6% higher than airborne-particle abrasion. After thermocycling, acid-etched specimens maintained the highest retention, whereas airborne-particle abrasion showed critical loss. SEM revealed predominantly cement remnants on zirconia in the acid-etched group, indicating a stronger zirconia-cement interface. Acid etching also yielded significantly lower contact angles, reflecting improved wettability. High-temperature hydrofluoric acid etching followed by silanization provided superior and more stable retention, more favourable failure modes, and improved wettability.