The mechanical behavior under compressive stresses of beta-tricalcium phosphate (beta-TCP) and hydroxyapatite (HA) scaffolds fabricated by direct-write assembly (robocasting) technique is analyzed. Concentrated colloidal inks prepared from beta-TCP and HA commercial powders were used to fabricate porous structures consisting of a 3-D tetragonal mesh of interpenetrating ceramic rods. The compressive strength and elastic modulus of these model scaffolds were determined by uniaxial testing to compare the relative performance of the selected materials. The effect of a 3-week immersion in simulated body fluid (SBF) on the strength of the scaffolds was also analyzed. The results are compared with those reported in the literature for calcium phosphate scaffolds and human bone. The robocast calcium phosphate scaffolds were found to exhibit excellent mechanical performances in terms of strength, especially the HA structures after SBF immersion, indicating a great potential of this type of scaffolds for use in load-bearing bone tissue engineering applications.

Distributed irreversible deformation in otherwise brittle ceramics (specifically, in silicon carbide and micaceous glass-ceramic) has been observed in Hertzian contacts. The deformation takes the form of an expanding microcrack damage zone below the contact circle, in place of the usual single propagating macrocrack (the Hertzian "cone fracture") outside. An important manifestation of this deformation is an effective "ductility" in the indentation stress-strain response. Control of the associated brittle-ductile transition is readily effected by appropriate design of weak interfaces, large and elongate grains, and high internal stresses in the ceramic microstructure.

The role of microstructural scale on deformation-microfracture damage induced by contact with spheres is investigated in monophase alumina ceramics over a range 3-48 pm in grain size. Measurement of a universal indentation stress-strain curve indicates a critical contact pressure -5 GPa, above which irreversible deformation occurs in alumina. A novel sectioning technique identifies the deformation elements as intragrain shear faults, predominantly crystallographic twins, within a confining subsurface zone of intense compression-shear stress. The twins concentrate the shear stresses at the grain boundaries and, above a threshold grain size, initiate tensile intergranular microcracks. Below this threshold size, classical Hertzian cone fractures initiate outside the contact circle. Above the threshold, the density and scale of subsurface-zone microcracks increase dramatically with increasing grain size, ultimately dominating the cone fractures. The damage process is stochastic, highlighting the microstructural discreteness of the initial deformation field; those grains which lie in the upper tail of the grain-size distribution and which have favorable crystallographic orientation relative to local shear stresses in the contact field are preferentially activated. Initial flaw state is not an important factor, because the contact process creates its own flaw population. These and other generic features of the damage process will be discussed in relation to microstructural design of polycrystalline ceramics.

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The fracture modes of hydroxyapatite (HA) scaffolds fabricated by direct-write assembly (robocasting) are analyzed in this work. Concentrated HA inks with suitable viscoelastic properties were developed to enable the fabrication of prototype structures consisting of a 3-D square mesh of interpenetrating rods. The fracture behavior of these model scaffolds under compressive stresses is determined from in situ uniaxial tests performed in two different directions: perpendicular to the rods and along one of the rod directions. The results are analyzed in terms of the stress field calculated by finite element modeling (FEM). This analysis provides valuable insight into the mechanical behavior of scaffolds for bone tissue engineering applications fabricated by robocasting.

Fracture damage in trilayers consisting of outer and inner brittle layers bonded to a compliant (polycarbonate) substrate and subjected to concentrated surface loading is analyzed. The principal mode of fracture is radial cracking at the undersurface of the inner (core) layer, even in the strongest of core ceramics--other damage modes, including radial cracking in the outer (veneer) layer, are less invasive in these all-brittle coating systems. Tests on simple trilayer structures fabricated from glasses, sapphire, and dental ceramics are used to examine the dependence of the critical load for radial fracture in terms of relative outer/inner layer thickness and modulus, and inner layer strength. An explicit relation for the critical load, based on a flexing plate model in which the outer/inner bilayer is reduced to an "equivalent" monolithic coating with "effective" composite modulus, is used to examine these dependencies. The theoretical relation describes all the major trends in the critical load data over a broad range of variables, thus providing a sound basis for trilayer design. Relevance of the analysis to dental crowns and other biomechanical applications is a central theme of the study.

An investigation is made of wear mechanisms in a suite of dental materials with a ceramic component and tooth enamel using a laboratory test that simulates clinically observable wear facets. A ball-on-3-specimen wear tester in a tetrahedral configuration with a rotating hard antagonist zirconia sphere is used to produce circular wear scars on polished surfaces of dental materials in artificial saliva. Images of the wear scars enable interpretation of wear mechanisms, and measurements of scar dimensions quantify wear rates. Rates are lowest for zirconia ceramics, highest for lithium disilicate, with feldspathic ceramic and ceramic-polymer composite intermediate. Examination of wear scars reveals surface debris, indicative of a mechanism of material removal at the microstructural level. Microplasticity and microcracking models account for mild and severe wear regions. Wear models are used to evaluate potential longevity for each dental material. It is demonstrated that controlled laboratory testing can identify and quantify wear susceptibility under conditions that reflect the essence of basic occlusal contact. In addition to causing severe material loss, wear damage can lead to premature tooth or prosthetic failure.

Contact-induced fracture modes in trilayers consisting of a brittle bilayer coating on a soft substrate were investigated. Experiments were performed on model transparent glass/sapphire/polycarbonate structures bonded with epoxy adhesive, to enablein situobservation during the contact. Individual layer surfaces were preferentially abraded to introduce uniform flaw states and so allowed each crack type to be studied separately and controllably. Fracture occurred by cone cracking at the glass top surface or by radial cracking at the glass or sapphire bottom surfaces. Critical loads for each crack type were measured, for fixed glass thickness and several specified sapphire thicknesses. Finite element modeling (FEM) was used to evaluate the critical load data for radial cracking, using as essential input material parameters evaluated from characterization tests on constituent materials and supplemental glass/polymer and sapphirse/polymer bilayer structures. The FEM calculations demonstrated pronounced stress transfer from the applied contact to the underlying sapphire layer, explaining a tendency for preferred fracture of this relatively stiff component. Factors affecting the design of optimal trilayer structures for maximum fracture resistance of practical layer systems were considered.