Casting defects

i) No Casting:

Causes:
1)sprue obstruction(investment fragment)
2) Metallic sprue former wasnt removed
3) molten alloy was not properly directed
to the mold cavity during casting.
4) Premature solidification of alloy during
casting ,causes may be:
a- Using a thick sprue leads to
premature entrance of the metal
into the mold cavity by its own
pressure and solidifies before
casting pressure is applied.
b- Low casting pressure.

c- Cold ring.

d- Incompletely heated or melted

alloy.

e- Fracture of the investment at the

base of the ring leading to metal
escape from the other side of the
ring (occurs due to increased
casting pressure or thin investment
bridge).
ii) Casting defects by
addition:
a) Frayed Margin ( fins ) :
caused by cracks in the investment
that have been filled with molten
metal.
These cracks can result from:
1. Premature or rough ring handling after
investing
2. Weak investment mix (high w/p ratio)
3. Too rapid heating
4. Improperly situated pattern (too close to ring
periphery resulting in a very thin investment
bridge)
b) Bubbles or nodules:
Bubbles of gas trapped between
the wax pattern and the investment
produce Nodules on the casting
surface can limit the seating of the
casting.
Causes are:

1- Air trapped during investing

procedure.
2- In adequate vacuum during
investing.
3- Improper brush technique.
4- Lack of surfactant.
5- Excessive vibration.
c) Rough surface:
The surface of the casting should be
smooth,
although finishing and polishing are
still required.
Surface roughness may be the
result of:
1- Presence of multiple bubbles on the
surface of
the wax pattern.
2- Rough surface of the wax pattern.
3- Increased water-powder ratio of the mix.
4- Excessive use of the wetting agent
5- Overheating of the investment.
6- Overheating of the metal.
7- Using investment material with large
grains.
iii) Incomplete Casting :
May result from:
1- Inadequate heating of the metal.
2- Incomplete wax elimination.
3- Excessive cooling ("freezing") of the
mold.
4- Insufficient casting force.
5- Not enough metal.
6- Metal spillage.
a) At the margin: may appear
as:

- Rough margin: is mainly due

to presence of foreign material (e.g.
piece of investment)
inside the mold cavity preventing
completion
of the margin.
- Round and convex margin: it is
mainly due to
insufficient casting pressure.
Alloy heating or casting in a cold
ring.
- Round and concave: is due to
entrapment of
air preventing the molten alloy
from entering the mold freely.
b) Perforated casting:
Perforation at the sprue attachment:
due to insufficient alloy. The
defected area is round and concave.
Perforation at thin areas: is due to lack of
accessory sprues .
iv) Intrinsic defects:
A.Porosity:
Porosity may occur within:
Interior region of a casting: weaken the
casting & if it extends to the surface
may be a cause for
discoloration.

On the external surface: is a factor in

surface roughness.
1) Back-pressure porosity:
caused by the inability of the air in the mold
to escape through the pores of the
investment.
a- Locating the pattern near the
end of the ring (6-8mm).
b- Insufficient venting of
investment
2) Gas inclusion porosity:
due to entrapment of gas in the molten alloy
during casting.
The cause of the gas may be:
a- Blow torch: If the reducing zone was
not used.
b- Affinity of some alloys to absorb
oxygen during heating.
c- Vapor may result from heating of the
investment.
d- Entrapment of oxides inside the
molten alloy.
3) Suck-back porosity:
Occurs if the metal in the sprue solidifies
before the metal in the mold :
a sprue is too narrow
too long or
incorrectly located.
4) Micro porosity:
Due to rapid solidification if the mold or
casting temperature is too low.
Is not detectable by naked eye.
It is important to mention that a rough
restoration produces a galvanic cell that
facilities tarnish and corrosion of the alloy.
5) Shrink-spot porosity (Localized):
Caused by shrinkage of a portion of a metal
when solidifies from the molten state.
6) Surface porosity : Due to :
1. Rough wax pattern.
2. Over heating of alloy.
3. Excessive use of wetting
agent.
7) Gas inclusion porosity (spherical) :
May be due to :
1. Poorly adjusted torch flame
(oxidizing
zone) .
2. Absence of the flux .
B.Dark discoloration that resists pickling:

Due to decomposition of calcium

sulphate binder of gypsum bonded
investment as a result of overheating.
The sulphur released binds with copper or
silver of gold alloy during casting
The casting must be
repeated.
v) Over or undersized casting:
Causes:
Improper investment selection regarding mold
expansion
Improper water powder ration
Ring liner
Mold heating

Dimensional inaccuracy leads

to marginal discrepancy ,therefore, remake is
mandatory
vi) Warped or distorted
casting:
causes for this type of failure:
1- Incorrect impression or die construction.
2- Incorrect handling of wax pattern before
investing.
3- Under estimation of wax relaxation due to
induced stresses or under estimation the
amount of setting and hygroscopic
expansion.
4- Incorrect positioning of the pattern in the
casting ring.
5- Using force during removal of the
restoration from the casting ring or
during
finishing and polishing.
Thank
You