This study evaluated the effect of four methods of metal surface preparatio
n and the use of silane on the bond strength between resin and a Noble meta
l alloy. SEM Examination and x-ray energy-dispersive spectroscopy (EDS) of
the various metal surface treatments was also performed. One-hundred metal
disks were cast in a Noble metal alloy (Porcelain #76). Ninety disks were p
olished flat and the surfaces received one of four abrasive treatments (n=2
0). 1) Roughening with a diamond bur at high speed; 2) Air abrasion with an
intraoral sandblaster using alumina particles; 3) Air abrasion with KCP-20
00 and 4) Air abrasion with an intraoral sandblaster using silanated silica
covered alumina particles (CoJet-Sand). Half the specimens from each treat
ment group (n=10) were silanated prior to bonding procedures (All-Bond 2 ad
hesive system, Pertac-Hybrid composite). Specimens were stored in distilled
water at 37 degrees C and thermocycled prior to shear strength testing. Th
e 10 remaining metal disks were used for scanning electron microscopy and x
-ray energy-dispersive spectroscopy (EDS). Scanning electron microscopy exa
mined the micromorphology of the metal surfaces produced by the four abrasi
ve treatments and x-ray energy-dispersive spectroscopy (EDS) to evaluate ch
anges in surface composition. Two untreated disks served as controls. One-w
ay ANOVA and Tukey's HSD post-hoc test demonstrated that air abrasion with
CoJet-Sand and silane resulted in significantly higher resin-to-metal bond
strength than all other metal surface treatments, while roughening with a d
iamond bur produced the lowest bond strength. Resin-to-metal bond strength
was similar for all other particle abrasive treatments with or without sila
ne. Using silane significantly improved bond strength only for metal surfac
es treated with CoJet-Sand. An increase in AZ concentration was observed on
metal surfaces sandblasted with aluminum oxide, and an increase in the con
centration of both AZ and Si was observed on surfaces air-abraded with CoJe
t-Sand.