The purpose of this study was to investigate the influence of chemical composition of Ni-Cr dental casting alloys on the bonding behaviour between porcelain and metal. A three-point bending test was used to measure the fracture load of alloy after porcelain firing. A scanning electron microscope, accompanied by an energy dispersion spectrometer, was used to analyse the morphology and chemical composition of the fracture surface. An X-ray photoelectron spectrometer and glow discharge spectrometer were used to identify the structure and cross-sectional chemical composition, respectively, of oxide layers on Ni-Cr alloys after heat treatment at 990 degrees C for 5 min. Results showed that the oxide layers formed on all Ni-Cr alloys contained mainly Cr2O3, NiO, and trace MoO3. The Ni-Cr alloy with a higher Cr content had a thicker oxide layer, as well as a weaker bonding behaviour of porcelain/metal interface. The presence of Al (as Al2O3) and Be (as BeO) on the oxide layer suppressed the growth of the oxide layer, leading to a better porcelain/metal bonding behaviour. However, the presence of a small amount of Ti (as TiO2) on the oxide layer did not have any influence on the bonding behaviour. The fracture propagated along the interface between the opaque porcelain and metal, and exhibited an adhesive type of fracture morphology.

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The cavitation characteristics at filler metal/substrate interface during ultrasonic-assisted soldering were first recorded by high-speed photography in this work. Two kinds of bubbles, steady cavitation bubbles and transient cavitation bubbles were observed. Steady cavitation bubbles did not collapse within one acoustic period and could last longer than 50 acoustic periods. Transient cavitation bubbles formed and collapsed within one acoustic period. The cavitation process was divided into two stages based on the cavitation characteristics. The first violent cavitation stage was in fact the degassing process, which lasted approximately 2700 acoustic periods and was affected by the gas content trapped inside the filler metal and the stronger vibration at the initiation stage of ultrasonic-assisted soldering. The second steady cavitation stage had obvious low bubble density and accounted for the most of the soldering process. Higher cavitation densities were observed when small channel width and large ultrasonic power were used because of larger sound pressures inside the filler metal.

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