CONTENTS

• Introduction
• Definitions
• History
• Wax Pattern
• Spruing
• Casting Ring and Liner
• Investing
• Burnout
• Casting Machines
• Casting
• Cleaning Of Casting
• Casting Defects
• Review Of Literatures
• Summary
• Reference
 INTRODUCTION
• Since the discovery of the earth’s minerals,
metal casting has played an important role in
the society. It has become an integral part of
every technological advancement. Casting has
allowed us to build equipments, machineries,
infrastructures and of course plays an
important role in dentistry.
 The casting process is used to make dental
restorations such as inlays, onlays, crowns,
bridges, and removable partial dentures.
Because casting must meet stringent
dimensional requirements, the casting process
is extremely demanding .
 DEFINITIONS
• 1) casting : something that has been cast in a
mold;an object formed by the solidification of
a fluid that has been cast into a refractory mold
• 2) casting ring: a metal or silicone tube in
which a refractory mold is made for casting
dental restorations

GPT 9
• 3)crucible former: the base to which a sprue
former is attached while the wax pattern is
being invested in re-fractory investment; a
convex rubber, plastic, or metal base that
forms a concave depression or crucible in the
refractory investment

GPT 9
• 4) Investing : the process of covering or
enveloping, wholly or in part, an object such
as a denture, tooth, wax form, crown, etc.,
with a suitable investment material before
processing, soldering, or casting
• 5) Lost-wax casting technique: the casting of
metal alloy or ceramics into a mold produced
by surrounding (investing) an expendable
(wax) pattern with a refractory slurry that sets
at room temperature, after which the pattern is
removed through the use of heat;

GPT 9
• 6) Refractory cast: a cast made of a material
that will withstand high temperatures without
disintegrating;
• 7) Refractory die: any die material that is
capable of enduring the high temperatures that
occur during firing or casting procedures; the
die is an integral part of the mold; the
restoration is directly cast,molded, or fired onto
the refractory die
GPT 9
 HISTORY
• The Era of casting began with the discovery
of copper casting by Mesopotomians in 3000
BC.
• The use of dental casting machines to fabricate
cast metal restoration is credited to the people
of the early Chinese civilization in the Bronze
Age

Asgar K. Casting metals in dentistry: past-present-future. Advances in

dental research. 1988 Aug;2(1):33-43.
 • Dental castings were first seen in the skulls of
people of the Chinese civilization where cast
metal restorations were fastened onto the
human teeth, with metal wires passing through
the space between the teeth.

Asgar K. Casting metals in dentistry: past-present-future. Advances in

dental research. 1988 Aug;2(1):33-43.
• The modern dental
casting machines
came into existence
only in the year of
1907 when Dr.
William H.Taggart
introduced the
pressure-casting
machine along with
Lost Wax Technique

Asgar K. Casting metals in dentistry: past-present-future. Advances in

dental research. 1988 Aug;2(1):33-43.
• This was followed by Jameson who
introduced the centrifugal-casting machine
and Solbrig who introduced the steam-
pressure casting machine.
• “William Kroll” in 1930 invented useful
metallurgical process for Ti and is considered
to be the father of Ti dentistry.

Anusavice “Skinners science of dental materials”. Tenth Edition.

• The world’s first Ti dental casting was
produced in 1977 B.G. Waterstrat et al at the
National Institute of Standards and Technology
in Gaithersburg.
STEPS IN
CASTING

Anusavice K.J. –“Phillips’ science of dental materials 11th edition, 2003

 WAX PATTERN
• In case of CPD:
Relief, blockout and beading in master cast
helps in transfer of design to refractory cast

Rudd K.D., Morrow R.M. – “Dental laboratory procedures” RPD , 1986

• In case of FPD:
• Two methods-
 In the direct method the pattern is prepared on
the tooth in the mouth. This method can be used
for small inlay restorations.

 In the indirect method a model ( die ) of the

tooth is first made and the pattern is made on the
die. The indirect method is used for all types of
restorations

Science of Dental materials – V Shama Bhat, 3rd edition

 WAX PATTERN REMOVAL
• The sprue former should be attached to the
wax pattern on the master die, provided the
pattern can be removed directly in line with its
path of withdrawal from the die.

Note: Avoid Distortion

Stored in cold water if investment is
delayed

Anusavice K.J. –“Phillips’ science of dental materials 11th edition, 2003

 Sprue Former
• Purpose:- To provide a channel through which
molten alloy can reach the mold in an invested
ring after the wax has been eliminated.

• Diameter and length of sprue depends on -

1. Type and size of pattern
2. Type of casting machine
3. Dimension of flask or ring
Anusavice K.J. –“Phillips’ science of dental
materials 11th edition, 2003
 • 3 Basic requirements of sprue:-
1) Must allow the molten wax to escape from
the mold.
2) Sprue must enable the molten metal to flow
into the mold with as little turbulence as
possible.
3) Metal must remain molten slightly longer
than the alloy that has filled the mold.

Anusavice K.J. –“Phillips’ science of dental materials 11th edition, 2003

 SPRUING
• Five general principles of spruing:
1. Sprue diameter
2. Sprue position
3. Sprue attachment
4. Sprue direction
5. Sprue length
 Sprue Diameter
• Select a sprue former with a diameter that is
approximately the same size as the thickest
area of the wax pattern.

Small pattern = Small sprue former

Large pattern = Large sprue former

Science of Dental materials – V Shama Bhat, 3rd edition

 Small pattern = Large sprue former = distortion

Surface roughness

Too short sprue

Large pattern =Small sprue former = Loc.shrinkage
porosity

suck back porosity

too long sprue

 • In case of FPD
• 10gauge (2.6mm) generally used
• 12 gauge is used for small patterns like
premolars

Rosenstiel SF, Land MF, Fujimoto J. Contemporary fixed

prosthodontics. 4rd ed
 Reservoir
• round ball or a bar located 1mm away from the
wax pattern.
• Reservoir should be positioned in the heat centre
of the ring
• This permits the reservoir to remain molten for
longer and enables it to furnish alloy to the
pattern until they complete solidification process

Anusavice K.J. –“Phillips’ science of dental materials 11th edition, 2003

 Sprue Position- FPD
• Often a matter of individual judgment, based on the shape
& form of the wax pattern.
• Some prefer placement at;
• Occlusal surface
• Proximal wall
• Just below a nonfunctional cusp
• Ideal area- point of greatest
bulk in pattern.

Rosenstiel SF, Land MF, Fujimoto J.

Contemporary fixed prosthodontics. 4rd ed
 Sprue Position - CPD
• Attached to thickest portion
• Never feed thick section through thin section
• 7mm clearance between wax pattern and side
of ring.
• 8-10 gauge round wax is used as main sprue in
mandibular cast while 6 gauge half round wax
is commonly used in maxillary cast.

Rudd K.D., Morrow R.M. – “Dental laboratory procedures” RPD , 1986

 • 7mm hole is made at the center of mandibular
cast for easy spruing.Baseplate wax is rolled
and inserted through the hole until it extend
10mm on to pattern side.
• Hole can be made in maxillary cast also if
design permits.
• Metal sprue cones- TICONIUM

Rudd K.D., Morrow R.M. – “Dental laboratory procedures” RPD , 1986

 Sprue Attachment
• The Sprue former connection to the wax
pattern is generally flared for high density gold
alloys, but it is often restricted for lower
density alloys.

• The sprue former should be attached to the

portion of the pattern with a largest cross
sectional area.

Anusavice K.J. –“Phillips’ science of dental materials 11th edition, 2003

• Types:
• 1)Direct Spruing: The flow of the molten
metal is straight(direct) from the casting
crucible to the pattern area in the ring.
• A basic weakness of direct Spruing is the
potential for suck-back porosity at the junction
of restoration and the Sprue.
2)Indirect Spruing:
• Molten alloy does not flow directly from the
casting crucible into the pattern area, instead
the alloy takes a circuitous (indirect) route.
• The connector (reservoir) bar is often used
• advantages such as greater reliability &
predictability in casting plus enhanced control
of solidification shrinkage
 Sprue Direction
• The Sprue former should be directed away
from any thin or delicate parts of pattern.
• It should not be attached at a right angle to a
broad flat surface. Sprueing should be done at
a 45-degree angle to the proximal wall.

Anusavice K.J. –“Phillips’ science of dental materials 11th edition, 2003

 Sprue Length
• The length of the sprue former depends on the
length of the casting ring.

• If the sprue is too short , the wax pattern may

be so far removed from the end of the casting
ring that gases cannot be adequately vented to
permit the molten alloy to fill the ring
completely. – Back pressure porosity

Anusavice K.J. –“Phillips’ science of dental materials 11th edition, 2003

• Sprue length should be adjusted so that the top
of the wax pattern is within 6mm of the open
end of the ring for gypsum bonded investments.

• With the higher strength phosphate bonded

investments position the wax pattern within 3
to 4 mm of the top of the investment for
reproducibility of casting accuracy, the pattern
should be placed as close as possible to the
center of the ring
 CRUCIBLE FORMER
• The sprue is attached to a
crucible former usually made
of rubber, which constitutes
the base of the casting ring
during investing.
• The exact shape of crucible
former depends on the type of
casting machine used.
 CASTING RING and LINER
• Split ring or flexible rubber ring is used

Compensate investment expansion

• Ring liner
 Casting Rings

Types Material Metal

Plastic
Shape Round
Oval
Design Complete.R
Split.R
 Casting Liner
• Types:
1. Asbestos
2. Non-asbestos Ring Liners:
• Ceramic (aluminum silicate)
• Cellulose (paper)
• Ceramic-cellulose combination
• The dry liner is tacked into position with
sticky wax, and it is then used either dry or
wet.
• With a wet liner technique , the lined ring is
immersed into water for a time , and the excess
water is shaken away.
• Wet liner also causes a semi hygroscopic
expansion as water is drawn into the
investment during setting.
• THICKER the LINER Greater the expansion
• In any case, the thickness of the liner should
not be less than approx. 1mm.
• Usually longitudinal setting expansion of the
investment is unrestricted with in casting ring.
• Place the liner somewhat short of the ends of
the ring, 3mm, tends to produce a more
uniform expansion, by confining the
investment at 1 or both ends.
 RINGLESS CASTING SYSTEM
• A ringless system that provides maximum
expansion ( PowerCast Rlngless System)
• This system is suited for the casting of alloys
that require greater mold expansion than
traditional gold-based alloys.
• consists of three sizes of
tapered rings and
formers, preformed wax
sprues and shapes,
investment powder, and
a special investment
liquid
 INVESTMENT PROCEDURE
• Wax pattern should not stand for more than
30min before investment
• Cleaning of wax pattern – Cleanser
Synthetic detergents
Debbublizer
• 3 types of investment materials:
 Gypsum bonded investments
 Phosphate bonded investments
 Ethyl silicate bonded investments
 Investment Techniques
1. Hand mixing
2. Vaccum mixing
 Hand Mixing Investment Technique

• Applicator used to paint on wax pattern

• Slight tilting of ring and use of vibrator
• Avoid excess vibration Surface
Roughness
Vaccum Mixing Technique
 Setting Of The Investment
• Normal Setting Expansion – 0.4%.
• Hygroscopic Expansion – 1.2 to 2.2%.
• Thermal Expansion - 1.3% .
• Total expansion should be greater than average
casting shrinkage.
• Wax pattern expansion also happens during
setting of investment
 Compensation Of Shrinkage
• Liners
• Liquid /powder Ratio
• Setting expansions
• Consistency
 BURNOUT
• Burnout - Process
of heating an
invested mold to
eliminate the
embedded wax or
plastic pattern.
• Burnout is immediately done as soon as
investment sets or else store in 100% humidity
• Purpose: Wax elimination and mold expansion
• Heated from Room temp to maximum temp

• For gypsum bonded investment

1)Low heat hygroscopic technique- 500ºC
2) High heat thermal expansion technique-
700ºC

• For Phosphate bonded investment- 700ºC to

1030ºC depending on alloy selected
 Wax Elimination
• Wax absorption by investment
• Entrapment of residual carbon
• Remedy: Wet investment
High Heat Technique- C to CO &CO2
 Hygroscopic Low Heat Technique
• Shrinkage compensation-
1. 37ºC water bath expands wax pattern
2. Warm water causes hygroscopic expansion
3. Thermal expansion at 500ºC
• Advantage: Direct placement of investment at
500ºC furnance possible. but sufficient
burnout time needed.
• Mold remains in furnance for 60min and can
remain up to 5hrs with little damage
• Disadvantage: Back pressure porosity
• Standardized H.Tech is for gold alloys
• Newer noble metal allows needs additional
expansion: a) water bath 40ºC
b) 2 layer liners
c) 600ºC to 650ºC
High heat thermal Expansion Technique

• Compensation of shrinkage:
1. Expansion of wax pattern
2. Water entering from wet liner
3. Thermal expansion at 700ºC
• Heated from room temp to 650ºC- 700ºC
over 60min and held for 15-30 min
• Problems faced: 1) Rapid heating leads to
cracks in investment resulting in fins and
spines in casting
2) too many wax patterns in same plane –
separation of investment
3) Excessive heating above 700ºC
CaSO4 + 4C CaS + 4CO
3 CaSO4 + CaS 4CaO + 4SO2
• Sulfur dioxide as a product of this reaction
contaminates gold castings & makes them
extremely brittle.
• Some crystobalite containing investment can
undergo rapid burnout procedure :-
- Placing the mold in a furnace at 315ºC for
30min. & then rapid heating. Or
- Directly place into a furnace at the final burnout
temp. held for 30min. & cast.
Phosphate Bonded Investment Material

• More setting and thermal expansion than GBI

• Burnout at 750- 1030ºC –Highest for base
metal alloys
• Slow heating till 315ºC and rapidly heated to
upper temparature.
• No more than 1min should be allowed to
elapse between time the ring is removed from
the oven and the molten alloy is centrifuged
into mold in case of HHTET while it should be
immediately casted in case of LHHET
• If not Mold contraction
 Casting crucibles
• Generally 4 types of casting crucibles are
available:-
- Clay ,
- Carbon ,
- Quartz, and Zirconia- alumina
.
• Clay - high noble (HN) and noble types.
• Carbon crucibles- HN & high fusing gold
based metal ceramic alloys

• Crucibles made from alumina , quartz or silica

are recommended for high fusing alloys of any
type.
 Casting Machines
• Classification:
1. Based on method of casting:
Centrifugal force Type
Vaccum type
Air pressure type
2. Based on method of melting alloy:- Torch melting
- Induction Melting
- Arc Melting
- Electrical resistance -heated
CASTING HIGH FUSING METAL-
CERAMIC ALLOYS:-

• It requires that the metal be heated approx.

200ºF(100ºC) higher than its upper melting
point.
• This is generally in range of 1200ºC-1370ºC.
• These temp. can be achieved with either:
- A gas oxygen torch, or
- Induction heating.
 Torch Melting
• The fuel used in most instances is a mixture of
natural gas and air or propane and air or
oxygen and acetylene or air and acetylene can
also be used .
• Temparature of flame depends on propotion of
various gases
• Acetylene-Colourless,Garlic like odour,
3000*f, Contaminated with C, not used in
metal ceramic
• Natural gas-2200*f, With oxygen used for
melting high fusing noble and base metal
alloys
• Propane -Clear consistent burn.
 Nonluminous Flame
Parts of the flame:
• Parts of the
flame can be
identified by the
conical areas:
• First long cone emitting directly from the
nozzle is the zone in which the air and gas are
mixed before combustion. No heat is present
in the zone.

• Second cone is the combustion zone which is

green and immediately surrounding the inner
cone. Here, the gas and air are partially
combusted.
• Third zone is the reducing zone which is dimly
blue. This is the hottest part of the flame and is
just beyond the tip of green combustion zone.
The area should be constantly on metal during
fusion.
• The next zone is an “oxidizing zone” and
therefore should always be kept away from the
metal during fusion (melting).
• When the reducing zone
is in contact, the surface
of the gold alloy is bright
and mirror like.

• When the oxidizing

portion of the flame is in
contact with alloy there is
a dull film of “dross”
developed over the
surface.
 Induction Melting
 Melting of alloy is by an Induction field developed
within Crucible surrounded by water cooled metal
tubing
 Alternating Current causes magnetic field.

AC + H2O causes raise in temp- 1500-1600ºC

Used for melting High fusing alloys

The melted metal is forced into the mold space

within the ring by centrifugal force, air pressure,
vacuum, or both
Electrical resistance heated casting machine

• In this device current is passed through a

resistance heating conductor, and automatic
heating of the alloy occurs in a graphite or
ceramic crucible.
• This is an advantage, especially for alloys such
as those used for metal ceramic prostheses
• Flush contact between crucible and casting
ring.
• Carbon crucible cannot
be used with high Pd
alloys, Pd-Ag alloy, Ni-
Cr alloy or Co-Cr alloy.
 Direct current arc melting machine

• The direct arc

current is produced
between to
electrodes ; the alloy
and the water cooled
tungsten electrode.
• The temperature within the arc exceeds
4000 C. and the alloy melts very quickly.
• This method has a high risk for over
heating the alloy and damage may result
after only a few seconds of prolonged
heating
• High fused metal like Ti
 Centrifugal Casting Machine
• The casting machine spring is first wound 2-5
turns.
• Once the metal is melted, the machine is
released and the spring triggers the rotational
motion.
• Principle: This machine utilize the centrifugal force
which is defined as a radical force radiating outward
from the center of rotation of a body, for casting.
• The machine works on ‘broken-arm’ principle
where the crucible is attached to the broken-arm,
which accelerates the effective initial rotational
speed of the crucible and casting ring thus
increasing the linear speed of the liquid casting alloy
as it moves into and through the mold.
• To counter the weight of the molten metal in
the crucible and casting ring, balancing arm is
provided with the balancing weights.
• The metal / alloy pellets are heated in the
crucible with the flame/blowpipe and the
casting ring is positioned with the snout of the
crucible fitting the space left by the crucible
former in the casting ring.
• Once the alloy / metal is in a molten form, the
casting ring and crucible in position, the flame
is removed and the broken-arm is released and
the hand is withdrawn immediately to prevent
accidents.
• The broken-arm sets in rotation and pushes
the molten metal / alloy into the mold by
centrifugal force. Once the metal fills the mold
there is a hydrostatic pressure gradient
developed along the length of the casting.
• The pressure gradient from the tip of the casting
to the button surface is quite sharp and parabolic
in function, coming to zero at the button surface.
• Because of this gradient there is also a gradient
in the heat transfer rate, such that the greatest
rate of heat transfer to the mold is at the high
pressure end of the gradient (i.e. the tip of the
casting). Therefore, solidification progresses
from tip to the button side.
 Vacuum or Pressure ,Assisted Casting
Machine
• For this method , the molten alloy is heated to the
casting temperature, drawn into the evacuated
mold by gravity or vacuum.

• Then subjected to additional pressure to force the

alloy into the mold.

• For titanium and its alloys vacuum arc heated

argon pressure casting machines are required.
• In 1978 ,Wilmer B. Eames and John F.
MacNamara evaluated the performance of four
different casting machines in producing accurate
and sharp margins. They concluded that:
• Vacuum casting machines produced sharper
margins than the centrifugal casting machines.

Eames B.W. “Evaluation of casting machines for ability to cast sharp margins”. J
Oper Dent 1978; 3: 137-141.
• T.E. Donovan and L.E. White in 1985 studied the
increase in castability of an alloy by increasing the
rate of acceleration of the centrifugal casting
machine. They used a vertical-motion centrifugal
casting machine which was rapidly accelerated by the
operation of a pneumatic cylinder and piston and
compared it with a conventional broken-arm
horizontal centrifugal casting machine.
 • They observed the vertical rotating centrifugal
casting machine produced more number of
complete mesh filament specimen than
horizontal rotating centrifugal casting
machine.

Donovan T.E., White T.E. “Evaluation of an improved centrifugal casting machine”. J

Prosthet Dent 1985; 53: 609-612
 AIR PRESSURE CASTING MACHINE

• Uses compressed air,gas,co2,nitrogen to force

the molten metal into the mold cavity.
• Advantage : reduced surface irregularities
• Disadvantage :1. oxidation of metal occurs
causing reduction in mechanical properties.

• 2.only small castings.

• H. Hamanaka, H. Doi et al in 1989 devised a
new casting machine for dental casting of
titanium and Ni-Ti alloys. In this new casting
machine, the gas in the mold was removed by
heating the mold in high vacuum thus reducing
the chances of oxidation of the titanium metal/
or the alloy during casting.
 • he argon gas which flooded the chamber during the
melting of the alloy was evacuated at the starting of the
casting procedure. This prevented the inclusion of the
argon gas in the castings leading to “blow-in” porosities in
the cast structures. 
• Once the molten metal / alloy dropped in the mold from
the split copper crucible, the argon gas was again
introduced which pushed the molten metal into the mold.

Hamaka H., Doi H., Yoneyama T., Okuno O. “Dental casting of titanium and Ni-Ti
alloys for a new casting machine”. J Dent Res 1989; 68: 1529-1533.
 Cleaning Of Casting
Quenching
• After casting has been completed, the ring is
removed & quenched in water as soon as the
button exhibits a dull red glow.
• Metal ceramic or base metal alloys should not
be quenched
• Advantages of quenching:-
1) The noble metal alloy is left in an annealed
condition for burnishing, polishing & similar
procedures.
2) When water contact with hot investment, a
violent reaction ensues. The investment
becomes soft & granular & the casting is more
easily cleaned.
 Pickling
• Pickling is the process for the removal of
surface tarnish or oxidation.
• One of the best pickling solutions for gypsum
bonded investments is a 50% hydrochloric
acid solution. it aids in the removal of any
residual investment, as well as of the oxide
coating.
• 'The disadvantage of hydrochloric acid is that
the fumes from the acid are likely to corrode
laboratory metal furnishings and are
hazardous for health.
• Noble metal or high noble metal alloys -50%
sulfuric acid.
• In case of PBI, ultrasonic devices are useful
for cleaning.
• HCl or H2SO4 not effective for PBI or silica
refractory.
• Old HF acid- Silica refractory
• The pickling solution should be renewed
frequently, because of contamination after
reusing the solution several times.
• In no case should the casting be held with steel
tongs so that both the casting and the tongs
come into contact with the pickling solution.
• Gold-based and palladium-based metal-
ceramic alloys and base metal alloys are
bench-cooled to room temperature before the
casting is removed from the investment.
• Castings for these alloys are generally not
pickled, and when pickling is recommended
for certain metal-ceramic alloys, it is only to
selectively remove specific surface oxides.
 Sandblasting
• The process of altering the surface of a
material through the use f abrasive particles
propelled by compressed air or other gases
(GPT 9)
• Indicated – casting of BASE METAL
ALLOYS
• Common medium – 100µ – 150µ Aluminium
oxide
• Medium recycled every 30- 40 min.
• 60- 80 psi – force
• Uses: Cleaning, surface treatment
 CASTING
DEFECTS

INCOMPL DISTO
ETE
CASTING RTION

PORO SURFACE
ROUGHN
SITY ESS
 DISTORTION
1.Dist 1.Proper

PREVENTION
CAUSES

ortion manipul
ation
of wax and
pattern handlin
2.Setti g of wax
ng and pattern
2.Less
hygros
setting
copic expansi
expans on
ion of investm
invest ent
3.Less
ment thicknes
3.Thic s causes
kness more
of wax distortio
pattern n
 SURFACE ROUGHNESS
• It is defined as relatively finely spaced surface
imperfections whose height, width and
direction establish the predominant surface
pattern
• S. irregularities are isolated imperfections
such as nodules , that do not characterize the
total surface area.
 CAUSES
• Air bubbles • Composition of the
• Water film investment
• Rapid heating rates • Foreign body
• Under heating • Impact of molten
• Liquid :powder ratio alloy
• Prolonged heating • Pattern position
• Temperature of the alloy
• Carbon inclusion
• Casting pressure
 AIR BUBBLES
Gets Mecha

Prevention
Cause

nical
attac
mixer
hed with
to the vibrato
patter r
Applic
n
ation
durin of
g wettin
/subs g agent
in thin
eque
layers
nt to and air
inves drying
tment it.
 WATER FILMS
1.No 1.Pro

PREVENTION
CAUSE

intima per
te
contac appli
t of catio
the n of
invest the
ment
wetti
with
wax ng
pattern agent
2.Too 2.pro
high perL:
L:P
P
ratio
ratio
 UNDER HEATING
Heating time is too
short/insuffient air is Incomplete wax
available in the elimination
furnance

C residue

Difficult to
Voids/poros
remove by
ity picking
 RAPID HEATING RATES
Too Heat

PREVENTION
CAUSES

rapid the
heatin ring
g gradua
cracks lly to
the 700*(i
invest n
ment atleast
resulti 1 hour)
ng in Greate
fins. r the
bulk
slower
the
heatin
g
 W:P RATIO

RESULT
CAUSES

Gi
ves
Hi rou
gh gh
W- er
P cas
rat tin
io g
 PROLONGED HEATING
1.Disi Com

Remedy
Cause

ntegrat
plete
ion
of the
mold casti
cavity ng as
2.deco soon
mposit
ion as the
produc ring
ts like is
S can heate
conta
minate
d and
the ready
alloy
TEMPERATURE OF THE ALLOY
Too Care
high should
temper be
ature taken
that
the
molten
alloy
is no
lighter
than
light
orange
 CASTING PRESSURE
Using
Too 15
lbs/sq
inch of
air
hig pressur
e
h or (gauge
pressur
too e of
0.10 to
low 0.14MP
a)or 3
cast to 4
turns of
ing centrifu
gal
casting
machin
e
COMPOSITION OF THE INVESTMENT
Ratio Invest
of ment
binder should
to meet
quartz the
influen
ADA
ces the
specifi
roughn
ess of cation
the 2
invest
ment
Coarse
Si
causes
coarse
casting
 FOREIGN BODY
Rough Appears
crucibl as sharp
well
e defined
former deficien
Carele cies
ssness Bright
in appeari
remov ng
concavi
al of ties due
former to flux
S being
conta carried
minati into the
mold
on
Black
casting
IMPACT OF MOLTEN METAL
Direct Glanci
impact ng
of the impact
molten is less
alloy damag
at ing
angle
of
90*.
 PATTERN POSITION
Too Space
many betwe
pattern en
s in pattern
same s
plane, should
Too be
closel atleast
y 3mm
…
 CARBON INCLUSION
• C from crucible improperly
adjusted torch c containing
investment.
• Leads to formation of carbides causing surface
irregularities
 OTHER CAUSE
• various gold alloys, such as solders, bits of
wire, and mixtures of different casting alloys
should never be melted together and reused.
The resulting mixture would not possess the
proper physical properties and might form a
eutectic phase with low corrosion resistance.
• Discoloration and corrosion may also occur.
 POROSITY
• Porosities in noble metal alloy castings may be
classified as.
• I. Solidification defects A. localised
shrinkage porosity
B. Microporosity
• 11. Trapped gases
A Pinhole porosity
B. Gas inclusions C.
Subsurface porosity
D. Back Pressure porosity
LOCALISED SHRINKAGE POROSITY

CAUSE Premature termination of the flow of molten

●

metal during solidification

SITE ●
Common in the sprue casting junction

PREVEN ●
Additional sprues at the site most distance from the
main sprue.
Extend sprue laterally within 5mm of edge of the
TION
●

ring.(chill set sprue to carry heat away from pontic

 MICROPOROSITY

CAUSE Solidification is too rapid

●

●
Mold/casting temp is too low

Can only be seen if

SITE
●

sectioned
 PIN HOLES

Cu & Ag Molten Pt & Pd

Upon
have strong
solidification -oxygen in
affinity for
dissolved gases large amounts Hydrogen and
are expelled in liquid state oxgyen
SUBSURFACE POROSITY
Reason PREV
is ENTI
comple ON
tely not Contro
known. lling
May be
the
caused
rate at
by
simulta which
neous the
nucleat molten
ion of metal
solid enters
grains the
and gas mold
bubble
s
 ENTRAPPED AIR OR BACK PRESSURE
POROSITY
Lar De Pro
ge nse per
co inv bur
nc est n
av me out
e nt Ad
de Mo eq
pre re uat
ssi mo e
ons ld mo
Se de ld
en nsi an
in ty d
the Cl cas
ca og tin
vit gin g
y g te
sur wit mp
hC Hi
fac
du gh
e
e cas
of
to tin
M
lo g
O
w pre
D
hea ssu
cas t re
tin tec Pro
g hni per
sur qu L:P
fac e rati
e o
 INCOMPLETE CASTING
• Insufficient alloy used
• Alloy not able to enter thin parts of mold
• Mold is not heated to casting temperature
• Premature solidification of alloy
• Sprues are blocked with foreign bodies
• Back pressure due to gases in mold cavity
• Low casting pressure
• Alloy not sufficient molten or fluid.
 PREVENTION
• Sufficient casting pressure.
• Metal must be heated to its correct fusion
temperature to make it less viscous.
• Proper time and temperature of burn out
should be maintained.
Review Of Literature