Effect of Sandblasting, Tribochemical Silica Coating, CO2 Laser, and Plasma-Enhanced Chemical Vapor Deposition on Surface Characteristics and Shear Bond Strength of 3Y-TZP Zirconia

To evaluate the influence of different surface conditioning protocols—sandblasting (SB), tribochemical silica coating (TBC), CO2 laser irradiation, and plasma-enhanced chemical vapor deposition (PECVD-Si coating for 49 min) on surface roughness (Ra), surface morphology, and composite-to-zirconia shear bond strength (SBS). Eighty 3Y-TZP plates were randomly allocated into four groups (n = 20) based on surface conditioning protocol: Group 1 (SB), Group 2 (CO2 laser), Group 3 (TBC), and Group 4 (PECVD-Si coating for 49 min). From each group, five specimens underwent Ra assessment using a contact profilometer, and five specimens were examined for surface morphology via scanning electron microscopy (SEM). The remaining ten specimens received resin composite buildup, followed by artificial aging. Subsequently, SBS testing was performed using a universal testing machine, and failure modes were evaluated under a stereomicroscope. Statistical analysis was conducted using one-way ANOVA with post hoc Tukey test and chi-square for fracture assessment(α = 0.05). Group 1 (SB) demonstrated the lowest Ra (0.844 ± 0.063 µm) and SBS (12.21 ± 4.6 MPa), whereas Group 4 (PECVD-Si coating for 49 min) exhibited the highest Ra (1.388 ± 0.098 µm) and SBS (30.48 ± 2.5 MPa). Intergroup comparison revealed no statistically significant differences between Groups 2 and 3 for both Ra and SBS values (p > 0.05). However, Groups 1 and 4 differed significantly in both parameters (p < 0.05). PECVD-based silica coating for 49 min demonstrated superior surface conditioning efficacy for 3Y-TZP, yielding significantly higher Ra and SBS values compared to sandblasting, tribochemical silica coating, and CO2 laser irradiation.