 DISTORTION

 DISCOLORATION

 SURFACE IRREGULARITIES

 SURFACE ROUGHNESS

 POROSITIES

 INCOMPLETE CASTING
 DISTORTION
 CAUSE----DUE TO DISTORTION OF THE WAX
PATTERN

 DURING---PLACEMENT
 ---SPRUE ATTACHMENT
 ---PLUS CONTACT PLACEMENT
 ----DELAY IN WAX PATTERN INVESTING
MINIMIZED BY—

 PROPER WAX MANIPULATION

 INVESTING PATTERN IMMEDIATELY

 DISCOLORATION

CAUSES
 ---OXIDES IN MOLTEN METAL AND LACK OF
FLUX
 ---USE OF YELLOW ZONE OF HEATING TORCH
 ---UNDERHEATING OF INVESTMENT RING---WAX
REMNANTS ARE PRESENT---DISCOLORS CASTING
 ---OVERHEATING OF GYPSUM INVESTMENT
 ---SOLDERING—DISCREPENCY BETWEEN PARENT
AND SOLDERED METAL—GALVANIC CELL
FORMED—DISCOLORS CASTING
 MIXING OF OLD AND NEW CASTING
 MERCURY CONTAMINATION

AVOIDED BY
 FLUX APPLICATION TO MOLTEN METAL
 AVOID EITHER UNDERHEATING OR
OVERHEATING OF THE INVESTMENT
 USING THE BLUE REDUCING ZONE FOR
HEATING METAL
 DURING MIXING OF OLD AND NEW CASTING---
KEEP IT AT 50%
 AVOIDING MERCURY CONTAMINATION

 SURFACE IRREGULARITIES
(larger,severe ,irregular distribution)
NODULES/BLEBS

CAUSE----DUE TO AIR BUBBLE INCORPORATION

DURING INVESTING

AVOIDED BY---
 WASHING THE WAX PATTERN WITH SOAP
SOLUTION
 SURFACTANT APPLICATION
 VIBRATION OF MIX , VACUUM MIXING
 DOUBLE POUR TECHNIQUE OF INVESTING
BLEBS AND VEINS
 VEINS/RIDGES
 CAUSE—DUE TO WATER FILM INCORPORATION
(AT THE WAX –INVESTMENT INTERFACE)
DURING INVESTMENT

 AVOIDED BY
 ---PROPER POWDER : LIQUID RATIO
 ---DOUBLE MIX TECHNIQUE
 ---AVOID EXCESS VIBRATION
 FINS /SPIKES
CAUSE—DUE TO CRACKING OF INVESTMENT ON
RAPID HEATING

AVOIDED BY
 HEATING GRADUALLY FROM ROOM
TEMPERATURE TO 700 O C
 OTHER CAUSES OF SURFACE
IRREGULARITIES

 INVESTING MANY PATTERNS IN THE RING—THE

INVESTMENT INBETWEEN IS THIN AND CANNOT
TAKE THE CASTING PRESSURE—IT SHATTERS---
RESULTS IN SURFACE IRREGULARITIES
 EXCESSIVE CASTING PRESSURE---ABRADES THE
MOLD SURFACE—SURFACE IRREGULARITY ON
CASTING
 INCORPORATION OF FOREIGN BODY

CAUSE---CHIPPED OFF INVESTMENT AT SHARP

AXIOPULPAL LINE ANGLE
----CORRODED SPRUE

 AVOIDED BY----AVOID CORRODED METAL SPRUE

-----ROUNDING OF AXIOPULPAL LINE
ANGLE IN THE CAVITY PREPARATION
 SURFACE ROUGHNESS
(milder,smaller and regular in distribution)
CAUSES
 --COMPOSITION OF THE INVESTMENT
MATERIAL
(large size of silica fillers)

 LACK OF APPLICATION OF SURFACTANT---

improper adaptation of wax –investment interface
 PROLONGED HEATING---surface investment
starts to shatter

 HIGHER WATER: POWDER ratio—weaker

investment---shatters on application of
casting pressure
 HIGHER TEMPERATURE OF MOLTEN METAL----
oxides are picked up
AVOIDED BY---melting alloy only to 100-
150 0 c over the casting ring
temperature

 EXCESSIVE CASTING PRESSURE

 POROSITIES
 CANNOT BE TOTALLY ELIMINATED BUT
COULD BE MINIMISED

CAN OCCUR BOTH ON

 INTERNAL(decreases strength of casting,
discoloration and if extends to the surface, it causes
plaque accumulation and secondary caries) and
 EXTERNAL (surface roughness, tarnishes and
corrodes—difficult to finish and polish)
 CLASSIFICATION
DEPENDING ON THE CAUSE--
 A)SOLIDIFICATION DEFECTS
1)LOCALISED SHRINKAGE POROSITY
2)MICROPOROSITY

 B)TRAPPED GASES
1)PIN HOLE POROSITY
2) GAS INCLUSION POROSITY
3)SUB SURFACE POROSITY

 C)RESIDUAL AIR
BACK PRESSURE POROSITY
SOLIDIFICATION DEFECTS
LOCALISED SHRINKAGE POROSITY
CAUSE—PREMATURE TERMINATION OF THE FLOW
OF METAL DURING SOLIDIFICATION

OCCURS AT—JUNCTION OF WAX PATTERN AND

SPRUE

DUE TO---NARROW SPRUE—THUS MOLTEN METAL

STARTS TO HARDEN BEFORE ENTERING THE
MOLD SPACE
AVOIDED BY—PROPER SPRUE DIAMETER
---RESERVOIR PLACEMENT
 SUCK BACK POROSITY
 IT IS A LOCALISED SHRINKAGE POROSITY THAT OCCURS
EXTERNALLY ON THE INTERIOR SURFACE NEAR THE AREA
OF THE SPRUE, OPPOSITE A HOT SPOT (a higher mold
temperature area created where the hot metal impinges onto the
mold)

 OCCURS AT---INNER SURFACE OF CASTING OPPOSITE

THE AXIOPULPAL LINE ANGLE

 DUE TO ---HOT SPOT CAUSES THE METAL IN THAT

REGION TO FREEZE LAST RESULTING IN A SUCK BACK
POROSITY
 AVOIDED BY—FLARING THE POINT OF SPRUE
ATTACHMENT
 ---REDUCING THE MOLD—MOLTEN METAL
TEMPERATURE DIFFERENTIAL (by 300c )
 MICROPOROSITY
 OCCURS FROM SOLIDIFICATION SHRINKAGE

 SEEN IN
---- FINE GRAIN ALLOY CASTINGS WHERE
SOLIDIFICATION IS VERY RAPID AND CREATES
MICROVOIDS

-----RAPID SOLIDIFICATION IF MOLD OR CASTING

METAL TEMPERATURE IS LOW

 SEEN AS---SMALL IRREGULAR VOIDS

DUE TO TRAPPED GASES
PIN HOLE POROSITY
GAS INCLUSION POROSITY

 DUE TO—GAS ENTRAPMENT DURING MELTING --

-WHICH GETS EXPELLED DURING
SOLIDIFICATION

 SEEN AS—SPHERICAL POROSITIES ( GAS

INCLUSIONS BEING LARGER INSIZE)

 MINIMIZED BY—
---PREHEATING METAL ON GRAPHITE CRUICIBLE
--PROPER ADJUSTING AND POSITIONING OF THE
TORCH FLAME (blue reducing zone to be used)
 SUBSURFACE POROSITY

 CAUSE—SIMULTANEOUS NUCLEATION OF
METAL GRAINS AND GAS BUBBLES AS THE
MOLTEN METAL FREEZES AT THE WALLS
DUE TO RESIDUAL AIR
BACK PRESSURE/ ENTRAPPED AIR
POROSITY
 SEEN ON –INNER SURFACE OF CASTING AS LARGE
CONCAVITIES /OUTER SURFACE IF MOLD /CASTING
TEMPERATURE IS LOW THAT SOLIDIFICATION OCCURS
BEFORE AIR ESCAPES

 DUE TO---ENTRAPPED AIR IN THE MOLD

 SEEN IN—USE OF DENSE INVESTMENTS

--VACUUM INVESTED
--MOLD CLOGGED BY CARBON
 AVOIDED BY—PROPER BACK UP INVESTMENT THICKNESS
---VENT PLACED IF BACK UP INVESTMENT IS THICK
---LARGER FILLER PARTICLE SIZE
 INCOMPLETE CASTING
CAUSES

 INSUFFICIENT VENTING OF THE MOLD(due to back

pressure exerted by air in the mold)
Avoided by---proper casting pressure applied for 4 sec
Seen as –rounded incomplete margins

 WAX PATTERN NOT MELTED OUT( combination of molten

alloy with wax produces gases causing back pressure)
Seen as---rounded margins ,shiny (due to reducing environmemt
created by carbon monoxide)
 INADEQUATE MELTING OF ALLOY

 DISLODGEMENT OF WAX PATTERN

 NARROW SPRUE---metal not flowed into mold

space completely---(avoided by---Reservoir
placement)
 FOREIGN BODY BLOCKAGE

 INCORPORATION OF FLUX