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GOLD CASTING ALLOYS
Stephen C. Bayne
University of Michigan
School of Dentistry
Ann Arbor, Michigan
sbayne@umich.edu
INDIRECT RESTORATIONS
Overview of Errors
ERRORS:
Impressions
Models/Casts
Waxing
Investing
Casting
Finishing/Polishing
Cementing
0.1 to 0.2%
------
------
+1.5 to 1.7%
-1.5 to 1.7%
------
------
Calculation of ideal permissible error:
2 x 25 m / 10,000 m = 0.5%
*Image source: Steve Bayne, University of Michigan, 2008
**Image source: Undetermined
*
*
**
**
**
**
**
**

0. Fabrication requirements vs final properties:

1. Physical Properties:
a. Reasonably low MP (flow)

b. Moderately high density (castability)






c. Low coefficient of thermal expansion ()




2. Chemical Properties:
a. Chemical corrosion (tarnish) resistance
b. Electrochemical corrosion resistance
c. Solubility (solderability)
GENERAL REQUIREMENTS

Platinum = 12.45 gms/cm
3
Cobalt = 8.90

Gold = 18.88 Nickel = 8.90
Palladium = 12.02 Iron = 7.87
Silver = 10.50 Chromium = 7.17
Copper = 8.96
Tooth = 9-11 ppm/C Amalgam = 25
PFM alloys = 14 Composite = 35-45
Gold alloys = 18

3. Mechanical Properties:
a. High E (stiffness)
b. Moderately high YS and H (resistance to plastic deformation)
c. Hardenable by heat treatment (retention of polish)












4. Biological Properties:
a. Biocompatible: no toxic soluble phases
b. Non-reactive in the oral environment
GENERAL REQUIREMENTS
(continued)
S
T
R
E
S
S

STRAIN
x
Yield Strength (or Hardness)
Modulus (Stiffness, Slope of Line)
x
Graph source: Steve Bayne, University of Michigan, 2008
REVIEW OF CORROSION
1. Types: Chemical Corrosion, Electrochemical Corrosion

2. Requirements for Electrochemical Corrosion:
Anode, Cathode, Circuit, Electrolyte












3. Electrochemical Corrosion Categories:
a. Galvanic Corrosion (macro-galvanic)
b. Local Galvanic Corrosion (structure-selective corrosion)
c. Concentration Cell Corrosion (crevice corrosion)
d. Stress Corrosion

Images source: Steve Bayne, University of Michigan, 2008
CLASSIFICATION OF ALLOYS
1. Full Gold Crown and Bridge Alloys (based on precious metals)

a. ADA Classification System (see phase diagrams)
(1) Type I 83% Au+ (Non-heat hardenable) -- inlay
(2) Type II 78% Au+ (Non-heat hardenable) -- inlay, onlay,
(3) Type III 78% Au+ (Heat hardenable) -- onlay, crown
(4) Type IV 75% Au+ (Heat hardenable) -- crown, bridge

b. Effects of Alloys Components:
(1) Gold (Au)
(2) Copper (Cu)
(3) Silver (Ag)
(4) Palladium (Pd)
(5) Platinum (Pt)
(6) Zinc (Zn)

Corrosion resistance
Hardness
Counteract orange color of copper
Increase MP and hardness
Increase MP
Prevent oxidation during melting (O
2
getter)
TERMINOLOGY
1. Precious Metal = containing metals of high economic value such as
gold, platinum, palladium, silver, (rhodium), (iridium), (rhuthenium),
and (osmium).

2. Noble Metal = a precious metal that is resistant to tarnish. This
excludes silver by definition.

3. Low Gold Alloys = Alloys containing <75% gold (less than 50 a/o gold)
which means that gold atoms represent less than every other atom.

4. Gold-substitute Alloys = precious metal alloys not containing gold.

5. Base-Metal Alloys = alloys not containing precious metals to impart
their corrosion resistance.
ATOMIC PERCENT GOLD CU AU
100
600
700
800
900
1000
500
400
300
200
10 70 80 90 100 30 40 50 60 20 0
1100
WEIGHT PERCENT GOLD
30 10 70 80 90 100 40 50 60 20 75 85 95
LIQUIDUS
SOLIDUS
DENTAL
ALLOYS
T
E
M
P
E
R
A
T
U
R
E

(

C

)

Low Gold Alloys High Gold Alloys
Random
Solid
Solution
Ordered
Solid
Solution
Graph source: Steve Bayne,
University of Michigan, 2008
AG CU
AU

+
5
10
15
20
25
30
35
40
50
45
AU-AG-CU
Tenary
Phase Diagram
Type I
Type II
Type III
Type IVI
T
Graph source: Steve Bayne,
University of Michigan, 2008
COMMERCIAL EXAMPLES
Graph source: Steve Bayne, University of Michigan, 2008
PROCESSING CYCLES
a
l
l
o
y

TIME

Alloy LCTE = 16-18 ppm/C

CAST
GOLD
ALLOYS
T
m
890C
T
rt
Graph source: Steve Bayne, University of Michigan, 2008
A. Distortion:

1. Margins: Probability highest in thinner portions of pattern.
a. Wax Deformation: improper removal or handling of pattern.
b. Premature Quenching: wait until button loses red color.
c. Investment Expansion/Contraction:
CASTING PROBLEMS
for Gold Alloys
a
b
c
Image source: Steve Bayne, University of Michigan, 2008
B. Surface Irregularities:

1. Fine Surface Roughness: Inherent particle size of investment
a. High W/P ratio increases surface roughness.
b. Low W/P ratio decreases investment adaptation or flow.
c. Prolonged burnout encourages investment decomposition.
d. Overheating alloy encourages investment decomposition.
e. Overheating alloy encourages reaction with investment.
2. Surface Defects:
a. Nodules: air bubbles trapped on the pattern during investing.
(Use surfactant; paint pattern; vacuum invest; vibrate)
b. Ridges or Veins: poor wetting causing water films on pattern.
(Use surfactant; vacuum invest; vibrate investment carefully).
3. Gross Surface Defects:
a. Fins: cracked investment (from overheating)
INVESTMENT ALLOY
Nodules
Ridges or veins
Fins
Surface
roughness
CASTING PROBLEMS
for Gold Alloys
Image source: Steve Bayne, University of Michigan, 2008
C. Incomplete Castings:

1. Internal Porosity: due to improper solidification.
a. Improper Spruing: Diameter too small or too long.
b. Low Temperature: Investment or metal too cold.
c. Included Gases: Contaminated gold or oxidized old gold.
d. Occluded Gases: Improper burnout of pattern.
2. Incomplete External Shape:
a. Insufficient casting pressure.
b. Excessive back pressure from investment.
c. Suck back into sprue.
Internal
porosity
Incomplete
margin
Gas
bubble
CASTING PROBLEMS
for Gold Alloys
Image source: Steve Bayne, University of Michigan, 2008