CASTING PROCEDURES AND DEFECTS

Presented by: Dr. Pallavi B. Gopeshetti, CODS, Dvg.

CONTENTS
CONTENTS

Introduction & History Definition Dimensional changes in lost wax technique Accuracy of lost wax technique Steps in metal casting procedure Direct & Indirect wax patterns Impression making & Dies Preparing the wax pattern for investing -variables & principles of sprue design -crucible former -casting ring -ringless casting system -casting ring liners.

Investing the pattern -investment materials -hand investing -vacuum investing -high & low heat technique -controlled water- added technique Burnout of the wax pattern & heating of the ring Accelerated casting method Casting procedure Gas torch flame -melting of the alloy Electrical energy -casting crucibles -casting machines -a) air pressure casting machines b) vacuum pressure casting machines c) centrifugal casting machines -casting technique Recovery & cleaning the casting Finishing the casting Cementing the casting

CASTING DEFECTS -distortion -surface roughness & surface irregularities -porosities -discoloration - incomplete casting References Conclusion

INTRODUCTION

HISTORY

WILLIAM H.TAGGART(1855-1933), He
demonstrated on fabrication of cast inlay restoration developed in 1905 before the New York Odontological Society in 1907.

CASTING is defined as the process in which molten material is

poured into a mold and allowed to hardened into the shape of the mold.

LOST WAX TECHNIQUE is so named because wax pattern of a

restoration is invested in a investment material, then the pattern is burned out (lost) to create a space into which molten metal is placed or cast.

DIMENSIONAL CHANGES IN LOST WAX TECHNIQUE

Wax shrinkage + metal shrinkage(1.25-2.5%)= setting expansion+ hygroscopic expansion + thermal expansion

ACCURACY OF THE LOST WAX TECHNIQUE

Tolerance limit 0.05% ( 2m)

STEPS IN METAL CASTING PROCEDURES

STEP 1: cavity preparation in the tooth STEP 2: Direct wax pattern OR impression of the prepared tooth STEP 3: Preparation of the die from impression & indirect wax pattern on the die STEP 4: Preparing the wax pattern for investing, includes sprue design, crucible former, casting ring & liners

STEP 5: Investing the pattern STEP 6: Burnout of the wax pattern STEP 7: Casting procedures STEP 8: Cleaning the casting STEP 9: Finishing the casting STEP 10: Cementing the casting.

STEP 1
CAVITY PREPARATION

STEP 2
A) DIRECT WAX PATTERN
Type I medium wax Indication.

B) IMPRESSION OF THE PREPARED TOOTH

A) PREPARING A DIE FROM IMPRESSION

Most commonly useddental stone IV & V Disadvantage. Modifications.DIVESTMENT Other die materials. Recent advances

STEP 3

B) INDIRECT WAX PATTERN : type II soft wax

Die spacer: <0.5mm/ 10-30m Lubricants

Methods for removal of wax pattern

MOD PATTERN

MO/ DO PATTERN CROWN PREPARATIONS

STEP 4: PREPARING WAX PATTERN FOR INVESTING

VARIABLES & PRINCIPLES OF SPRUE DESIGN
SPRUE is defined as Purpose of the sprue

SPRUE FORMER

Type of sprue formers

waxes

metals

plastics

SPRUE DESIGNS

SPRUE DIAMETER :

5 PRINCIPLES OF SPRUE DESIGN

Diameter range: 6- 12 gauge( 4.1- 2mm) Too large??? Too small??? Narrow sprues indicated in.

Large inlay- 14 gauge( 1.6mm) Small inlay- 16 gauge (1.2mm) Large crowns, molars or metal ceramic crowns- 10 gauge (2.5mm) Small crowns or premolars or partial coverage restorations- 12 gauge (2.0mm)

SPRUE LENGTH:

Average length Too long sprue??? Too short sprue???

Large inlays: 4-5mm Small inlays: 3-4mm Large & small crowns: 4-5mm

SPRUE POSITION:

Bulkiest portion of the pattern because.

Largest non-centric cusps.

SPRUE ATTACHMENT:

Flared attachment/ constricted attachment.

At the largest cross-section of the pattern.

Direct spruing Indirect spruing

Reservoir:

SPRUE DIRECTION:

Away from thin delicate parts of the pattern 45 angulations

Not at 90 angulations

CRUCIBLE FORMER:

VENTING:

CASTING RING:

Average size: 29mm(1 1/8 ) diameter

38mm(1 ) in height

Split rings, flexible rubber rings.

RINGLESS CASTING SYSTEM.

Phosphate-bonded investments Paper & plastic casting rings

Powercast ringless system- whip-mix

CASTING RING LINERS: Asbestos liners Non-asbestos liners

Aluminosilicate ceramic liner Cellulose liner

Application wet - dry

Advantage??

STEP 5: INVESTING THE PATTERN

INVESTMENT MATERIALS
GYPSUM-BONDED INVESTMENTS:
-casting of gold metal alloys, melting point below 1200c for crowns & bridges & inlays

Properties:
-expansion -porous -strength -heating never >700c

PHOSPHATE- BONDED INVESTMENTS:

-alloys with higher melting range(>1200c) like metal ceramic restorations, higher melting gold alloys, base metal( chrome- cobalt), pure titanium & titanium alloys.

Properties:
-

Expansion Porosity Strength Temperature

SILICA- BONDED INVESTMENTS:

Alloys with high melting range like

Base metal alloys Chrome- cobalt alloys to make cast removable partial dentures

Disadvantage..

3.25mm

6mm

Wax pattern

Casting ring Ring liner

sprue

Investment material 3.25mm

Crucible former

INVESTING TECHNIQUE

Preparing the pattern- wetting agents Pattern should not stand for >20-30 mins Methods for investing-hand -vacuum

Preweighing of powder & liquid

HAND INVESTING:
Mechanical mixer-100 turns
For gypsumbonded.... For phosphatebonded investment

Paint investment on the pattern

Fill the casting ring

VACUUM INVESTING:

VACUUM MIXING:

VACUUM INVESTING: Techniquevac-u-spat investor Advantage ???

LOW HEAT TECHNIQUE:

NORMAL SETTING EXPANSI ON (0.7%)

LOW-HEAT
TECHNIQUE
HYGROS COPIC EXPANSI ON (1.5%)

HIGH HEAT TECHNIQUE:

NORMAL SETTING EXPANSIO N (0.7%)

HIGH-HEAT TECHNIQUE
THERMAL SETTING EXPANSION (1.25%)

CONTROLLED WATER ADDED TECHNIQUE:

Technique.

Why rubber rings ??? Purpose ???

Burnout ovens: manual, semiautomatic, fully programmable

STEP 6: BURNOUT OF THE WAX PATTERN

Position of the ring in furnace

Gypsum-bonded investments:

Temp.- 650c-700c in 60mins & held at higher

temp. For 15-30mins

-2 stage: keep in 200c preheated furnace for 30 mins,

later 480c for hygroscopic & 650c for thermal expansion & held for 45mins.

Precautions:
Avoid rapid heating of furnace Never heat above 700c CaSo4+ 4C CaS+4CO 3CaSo4+CaS 4CaO+4So4 Burnout wax when invst. is still wet..

Phosphate-bonded investment:
Temp: ranges from 750c - 1030 c Method: -slow till 315 c & rapid thereafter

-held in upper temp. for 30mins.

After Burnout:

Heating the ring ???

Immediately cast
Cherry Red color

ACCELERATED CASTING METHOD

Conventional:
1 hr bench setting for investment 1-2 hrs wax elimination

Accelerated casting method:

15 mins bench setting 15 mins wax burnout (815c)

STEP 7: CASTING PROCEDURE

MELTING OF THE ALLOY USING TORCH FLAME:
Types of gases: 1) natural gas( propane) & air
2) natural gas & oxygen 3) air & acetylene/oxygen & acetylene

Types of tips. Temp. 870-1000c Typical flame.

CONICAL FLAME

USING ELECTRICAL ENERGY

Types: -electrical resistance -induction melting -direct-current arc melting

ELECTRICAL RESISTANCE
Principle. Advantage

INDUCTION MELTING MACHINE

Principle Used for base metal, co- ch alloys, titanium alloys

DIRECT CURRENT ARC MELTING MACHINE

Principle Tempexceeds 4000c Disadvantage

Types. 1) Clay, graphite- crown & bridges, alloys of high noble metals
& noble types 2)

CASTING CRUCIBLES

Carbon- high noble crown & bridges, higher fusing gold based
metal ceramic alloys.

3)

Quartz, alumina, silica, ceramic - high fusing alloys

of any type and the sensitive to carbons.

AIR PRESSURE CASTING MACHINE: Principle: -pneumatic forces

-CO2 or nitrogen.. - pressure of 10-15 psi - thin sprue

CASTING MACHINES

Used for metal ceramic casts

VACCUM CASTING MACHINE Principle: -pneumatic forces Used for base metal alloys

CENTRIFUGAL CASTING MACHINE Types: *motor driven or spring driven

*vertical rotating casting machine or horizontal casting machine.

principle... broken arm principle pressure- 30-40 psi (0.21- 0.28 Mpa)
Crucible Balancing weight Metal Casting ring Handle

Locking arm

Amount of driving energy depends on: Density ii. Porosity iii. No. of sprues iv. Length of the sprue v. Diameter of the sprue vi. Size of the pattern vii. Amount of metal viii. Angulations & funneling of the sprue ix. Configuration of the pattern & details.
i.

CASTING TECHNIQUE

STEP 8: RECOVERY & CLEANING OF THE CASTING

Quenching Advantage

pickling- Gypsum bonded investments: 50% HCl- disadvantage

method of pickling precautions other pickling solutions

Galvanic cell

Phosphate bonded investments: Ultrasonics Cold hydrofluoric acid Sand blasting.. AlO(50), 100psi

STEP 9: FINISHING OF THE CASTING

Initial stage:
rubber, rag or felt wheels impregnated with abrasives like diamond, silicone carbide, emery, AlO, granet, sand, tripoli, rouge etc

Final stage: beilby layer

various oxides of tin & Al, small rag or chamois buffing wheel, iron oxide rouge

Finally polishing compound removal

STEP 10: CEMENTING THE CASTING

Shrinkage of 1.4- 1.5%

CASTING DEFECTS
CLASSIFICATION:
Surface roughness ALLOY INVESTMENT Nodules Ridges or veins Fins

1. 2.

3.
4.

Distortion Surface roughness & irregularities Porosity Incomplete or missing details

Gas bubble

Internal porosity

Incomplete margin

DEFECT AFFECTING THE SHAPE

DISTORTION Causes Prevention

DEFECT AFFECTING SURFACE

SURFACE ROUGHNESS is defined as.. SURFACE IRREGULARITIES is defined as

ALLOY Surface roughness

INVESTMENT Nodules Ridges or veins Fins

Causes & prevention

AIR BUBBLES:

WATER FILMS:
ALLOY INVESTMENT

Ridges or veins

RAPID HEATING RATES: fins

ALLOY INVESTMENT

Fins

UNDERHEATING:

PROLONGED HEATING:
LIQUID/ POWDER RATIO:

TEMRATURE OF THE ALLOY:

CASTING PRESSURE: air pressure- 0.10-0.14MPa centrifugal- 3-4 turns

COMPOSITION OF THE INVESTMENT: ADA No. 2

FOREIGN BODIES:

IMPACT OF THE MOLTEN ALLOY:

PATTERN POSITION: 3mm btn patterns CARBON INCLUSIONS:

POROSITIES
CLASSIFICATION: I) Solidification defects -localized shrinkage porosity
-microporosity

II) Trapped gases -pin hole porosity

-gas inclusion porosity -subsurface porosity

III) Residual air -back pressure porosity

SOLIDIFICATION DEFECTS
LOCALISED SHRINKAGE POROSITY: suck-back porosity

MICROPOROSITY
Fine grain alloys

TRAPPED GASES
PIN- HOLE POROSITY
Gas bubble Internal porosity

GAS INCLUSION POROSITY

Incomplete margin

SUB- SURFACE POROSITY

RESIDUAL AIR
ENTRAPPED AIR/ BACK- PRESSURE POROSITY

DISCOLORATION OF THE ALLOY

DEFECT AFFECTING SIZE

INCOMPLETE CASTING: causes..a) insufficient venting, b) incomplete wax elimination prevention..

LARGE CASTING SMALL CASTING

COMPLETE CASTING FAILURE

REFERENCES
1. 2.

3.
4. 5.

Phillip`s Science Of Dental Materials-11th Edition, Kenneth J Anusavice Restorative Dental Materials-11th Edition, Robert G Craig, John M Powers Dental Materials & Their Selection-3rd Edition, William J O`brien Materials In Dentistry. Principles & Applications2nd Edition, Jack L Ferracane Essentials Of Dental Materials- S H Soratur

6. Contemporary Fixed Prosthodontics- 3rd Edition, Rosenstiel, Land, Fujimoto 7. Fundamentals Of Fixed Prosthodontics-3rd Edition, Herbert T Shillingburg 8. Textbook Of Operative Dentistry- 2nd Edition, Vimal K Sikiri 9. www.google.com 10. Department of prosthodontics, casting laboratory. CODS, Davangere.

CONCLUSION
A DENT IN YOUR MERCEDES, A CRACK IN YOUR MOBILE, A TEAR IN YOUR BRAND NEW LOUIS PHILLIPPE, A SCAR ON A BEAUTIFUL FACE, A FRACTURE IN A TOOTH, NOT SO DESIRABLE RIGHT??? NOR ARE CASTING DEFECTS..