Purpose: The objective of this study was to evaluate the influence of the oxide layer removal procedure using acid on the roughness and internal fit of overcast universal castable long abutments (UCLAs) for a taper connection.

Materials and methods: For this, maxillary first premolars were waxed on the plastic sleeve of 15 UCLAs with a premachined interface. The specimens were overcast using the NiCr alloy, and the frameworks were randomly distributed to undergo one of two different oxide layer removal methods: blasting with 100-μm particles of aluminum oxide at 0.60-MPa pressure or bathing for 5 hours in 0.5% hydrofluoric acid. The surface roughness was evaluated by a light interferometer at the subcritical contour of each abutment. Next, the frameworks were attached to the respective analogs for internal fit evaluation. The central cross section of each assembly was exposed, and three regions were visualized by scanning electron microscopy (SEM): taper interface, axial wall, and index region. The premachined base was used as the control. The groups were compared using analysis of variance (ANOVA) and Tukey post hoc test (α = .05).

Results: The results showed that acid bathing produced intermediary roughness between premachined and blasted surfaces (P < .05). SEM images showed a sealed interface at the taper region of all groups, despite some irregularities after alumina blasting. Increased discrepancies at the axial wall and index region were found after the alumina blasting procedure (P < .05).

Conclusion: It was concluded that acid bathing should be used, instead of blasting to remove the oxide layer, to produce a better fit and smoother surface on UCLAs.