A SEMINAR PRESENTATION

Inlay Casting Waxes

&
Wax Pattern Fabrication

PRESENTED By-
VIJAY

1
 INTRODUCTION
• The waxes used in dentistry normally consists of two or more
components – natural or synthetic waxes, resins, oils, fats, and
pigments.
• Blending – to produce a material with the required properties for a
specific application.
• Waxes – thermoplastic materials which are solid at room temperature
but melt, without decomposition, to form mobile liquids
• They are, essentially, soft substances with poor mechanical properties

• Carnuba is the hardest wax. Imp constituent of inlay wax Q

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• Primary use in dentistry – to form patterns prior to casting (inlay wax)
• The first procedure in the casting of an inlay is the preparation of the dental
wax pattern
• The wax pattern – precursor of the finished cast restoration that will be placed
on the prepared tooth
• It defines the shape and size of the resulting restoration and is eventually
replaced by either a polymer or an alloy using the lost-wax technique.

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• In as much as the wax pattern is duplicated exactly through the
investing and casting technique, the final restoration can be no
better than its wax pattern
• Wax pattern fabrication – the most empirical of all the steps in cast
fabrication and the cause of most casting failure.
• A few extra minutes spent on the wax pattern can often save hours
that might be spent correcting the casting.
• Also, it is necessary to know about pattern waxes.

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 Some key terms……
• Dental wax – a low molecular weight ester of fatty acids derived from natural or
synthetic components such as petroleum derivatives that soften to a plastic
state at a relatively low temperature
• Inlay wax – a specialized dental wax that can be applied to prepared teeth or
dies to form direct or indirect patterns for the lost wax technique used for
casting metals or hot pressing of caramics

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• Direct wax technique – method by which a wax pattern is made
directly on the prepared tooth in the mouth
• Indirect wax technique – method by which a wax pattern is
prepared on a die
• Glass transition temperature – temperature at which a sharp
increase in the thermal expansion coefficient occurs, indicating
increased molecular mobility
• Coefficient of thermal expansion – defined as the change in
length per unit of the original length of a material when its
temperature is raised 1 K.
• Elastic memory – tendency of a solid wax form to partially return
to its original shape when it is stored at a temperature higher that
that to which it was cooled
• Flow – the relative ability of wax to plastically deform when it is
heated slightly above mouth temperature

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• Dental Waxes- Pattern waxes (inlay, casting, baseplate),
Processing Waxes (boxing,utility, sticky), Impression wax

Laboratory products-
Clinical products-
1.Boxing wax
1.Bite registration wax
2.Baseplate wax
2.Disclosing wax
3.Sticky wax
3.Utilty wax adapting and
4.Beading wax
altering impression trays
5.Utility wax
4.Low melting type I inlay
6.Hard ,med, soft type II inlay
waxes
waxes

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 Types of Inlay Waxes
• The ADA specification No.4 for dental inlay casting wax covers two
types of inlay wax -
• Type I – medium wax - employed for direct techniques.
• Type II – soft wax - employed for indirect techniques (somewhat
lower melting point).

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 COMPOSITION
• No. of formulas – reported – some are quite complex
• The essential ingredients –
• natural waxes (hydrocarbons of paraffin & microcrystalline
carnauba wax, candellila wax, & resins) – derived from mineral,
vegetable, or animal origins.
• And/or synthetic waxes – chemically synthesized analogs of
natural wax molecules – more homogeneous and pure than
natural waxes

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• Paraffin wax:
• Principal ingredient upto 40%-60%. Q
• A basic petroleum hydrocarbon, characterized by non-homogenecity in
the size of macromolecules and their spatial arrangement and
combinations.
• Wide melting or softening range depending on the molecular weight
and distribution of constituents.
• Different extents of coefficient of thermal expansion at different
temperatures.
• Tendency to flake when trimmed.
• Does not present a smooth, glossy surface. Q

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• This can be modified by adding other waxes and resins as modifying
agents.
• Carnauba wax or candelilla wax (upto 25-30%) reduce flow; improve
glossiness, increase melting range, decrease plasticity and increase
strength properties of the wax.
• In modern waxes, carnauba wax may be replaced by synthetic waxes,
which are compatible with paraffin. These help to improve the working
qualities.
• Resins (5%) added to reduce flakiness and assure smooth surfaces.
Gum dammer is a natural resin while polythelene or vinyl resins are
synthetic. Synthetic resins are more predictable.

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• Ceresin may replace part of paraffin to modify toughness and carving
characteristics of wax. Q
• Traces of fats are added to improve the plasticity.
• Montan wax

• Coloring agents -
blue, green, purple, red or other colour –
added to provide a suitable contrast against a die.
• Inlay waxes are usually produced in deep blue, green or purple rods or
sticks about 7.5 cm long and 0.64 cm in diameter.
• Some manufacturers supply the wax in the form of small pellets or
cones or in small jars.

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 DESIRABLE PROPERTIES
• When softened, the wax should be uniform workabiity over wide
temp range
• Color should contrast with the die or prepared tooth
• There should be no flakiness or surface roughening when wax is
bent and molded after softening
• It should be able to be carved to very thin layer for preciseness
• ADA specification no. 4 - requires the melted wax, when
vaporized at 500 C (932 F) should leave no residue in excess of
0.10% of original weight Q
• The wax pattern should be completely rigid and dimensionally
stable at all times until it is eliminated

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 Flow
• Type I inlay wax - exhibit a marked plasticity or flow, at temperature slightly
above that of mouth
• ADA sp. no. 4 - maximum flow permitted for type I waxes at 37 C is 1%. The
low flow permits carving and removal of the pattern from the prepared cavity
at oral temperatures without distortion.
• Both Type I and Type II waxes should have a minimal flow of 70% and
maximum flow of 90% at 45 C.
• At this temperature, the wax is inserted into the prepared cavity. If the wax
does not have sufficient plasticity, it does not flow into all the areas of the
preparation and reproduce the required detail.

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 Thermal Properties
• The thermal conductivity of inlay waxes is low
• Time is required both to heat them uniformly thoughout and to cool
them to body or room temperature.
• Expand as much as 0.7% with increase in temp. of 20C, or contract as
much as 0.35 % when cooled from 37 to 25 C
• Coefficient of thermal expansion – defined as the change in length per
unit of the original length of a material when its temperature is raised 1
K.
• They possess a high coefficient of thermal expansion. The average
coefficient of thermal expansion is 350 x 10-6/ C.
• Thermal expansion is not linearly related to temperature and varies
unpredictably.
• Substantially higher value than other

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 Inlay wax thermally expands or contracts more per
degree of temp. change than any other dental
materials.

• Porcelain – 6.6 • Pd-Ag alloy – 14.8

• Dentin – 8.3
• Pure Ti – 8.5
• Type II G I – 11.0
• Tooth enamel – 11.4
• Au-Pd alloy – 13.5
• Pure gold – 14.0
• Amalgam – 25.0
• Composite – 14-50
• Denture resin – 81.0
• Pit & fissure sealant –
85.0
• Inlay wax – 400.0

Ppm /o K
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• Non-crystalline solids do not have a definite melting temperature,
but rather they gradually soften as the temperature is raised. The
temperature at which there is an abrupt increase in the thermal
expansion coefficient, indicating increased molecular mobility – the
glass transition temperature (Tg)
• Some constituents of wax probably change crystalline form at this
temperature, and the wax is more plastic at higher temperatures.

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 Wax Distortion
• Probably most serious problem that can occur during forming and
removal of the pattern from the mouth or die.
• This distortion results from thermal changes and the relaxation of
stresses that are caused by contraction on cooling, occluded air,
molding, carving, removal, and the time and temperature of storage.
• A freshly made wax pattern tend to change its shape and size over
a period of time.

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 Residual stresses
• Molecules and macromolecules of ingredients of the wax are held
together with very weak forces. Therefore, the relationship of the
forming molecules to each other can be changed very readily
thereby changing dimension and shape of the mass.
• Induced stresses from the applied forces will manifest after
effects.
• Thermal energy, due to temperature rise, increases the thermal
vibration of the component molecules.
• The resulting thermal vibrations and stresses precipitate the
shape and dimensional changes.

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 MANIPULATION OF INLAY WAX
• Wax patterns must be made with the greatest care because many
faults in inlays can be traced to imperfect wax patterns.
• Faulty handling of the wax in the mouth or after it has been removed
from the tooth can lead to distortion and a faulty inlay.
• Inlay wax – expand when heated, contract on cooling and develop
internal strain which are released when warmed.

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 MANIPULATION OF INLAY WAX…….

• The inlay wax can be softened in hot water or using dry heat.
• Hot water bath 54- 60 degree C Q

• Generally, dry heat is preferred as the former can result in water

droplet inclusion that can splatter on flaming, smear the wax surface
during polishing and distort the pattern during thermal changes.

• Skinner 1958 – wax should always be softened by ‘dry heat’ and not
in a water bath lest the lower melting point of the constituents leach
into the water.

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 SPRUEING THE WAX PATTERN
• The main purpose – to provide a channel or inlet through which molten
alloy can reach the mold in an inverted ring after the wax has been
eliminated (sprue)

Q - sprue former?
Q – factors related to sprue which produce best result for casting?
Ans- sprue diameter, sprue position, sprue attachment, sprue direction
and sprue length

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 Sprue former material
• Several types of materials are used for sprues - wax, resin or metal.
a) Some resin and all wax sprue formers have the advantage of being
completely burnable.
• The resin or wax has a fusion temperature lower or almost same as
the pattern wax.
b) Metal sprue formers –
Disadvantage of probably stressing or distorting the sprue walls of the wax
pattern during removal.
Advantage of rigidity during investment.
• They can be solid or hollow.
• Hollow sprue formers - preferred as they are more retentive and supply
minimal heat to the pattern.

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• The metal sprue former must be mechanically removed.
• This could cause investment to loosen from the walls. To avoid
this, wax is coated over uniformly before investing so that at the
time of burn out, the sprue former comes out easily as the wax
melts.

• The sprue former surfaces should be very smooth so that the walls
of the inlet do not have any irregularities.
• The sprue formers should be cylindrical in shape so as to create a
rounded inlet for the mold

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 Diameter of the sprue
• Depends on the size of the wax pattern, the type of casting machine, and
the dimensions of the flask or ring in which is used to form the mold
• It should be matched to casting volume; larger wax patterns require
thicker sprues.
• Diameter is similar or slightly greater than the thickest area of the wax
pattern Q
• If the pattern is small, the sprue former must also be small because a
large sprue attached to a thin pattern may cause distortion of the pattern
• The sprue former should be attached to the portion of the pattern with the
largest cross-sectional area.
Generally the diameters of the sprue formers range between 0.8 mm
(18 gauge) to 3 mm (8 gauge) in diameter.
premolars- 14 gauge

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 Length of the sprue former
• It depends on the length of the casting ring.
• It should be such that it properly positions the pattern in the
casting ring within 6mm (1/4 inch) of the open end of the ring
for gypsum bonded investments, and 3-4 mm (1/8 inch) for
phosphate bonded investments. Q
• If sprue is short- wax pattern is too far away, gases may not
be properly vented to permit the alloy to fill the mold space
completely. Q- back pressure porosities
• The sprue former should not be too long so that the metal
will begin to solidify in the sprue and cause porosity in the
casting.

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 Number of sprues
• If the wax pattern has a thin area between the sprue and the
periphery e.g. MOD cavities, the wax solidifies first in the
reduced cross sectional area preventing complete filling of the
mold. Hence, two sprues are required.
• If two or more sprues are used, they should join together to
form a reservoir at the crucible former level in a reservoir larger
than all the sprues combined.

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 Location of sprues
• The sprue former must be attached to the bulkiest portion of the wax
pattern.
• Advantages of this include:
• Minimizes the stresses created by heat while attaching the sprue
• Ensures that the thinner cross-section of the mold will be completely
filled.
• The melt will always be available until all lesser dimension sections are
completely filled.

Q- Sprue formers should be attached to the least anatomical area in the

wax pattern i.e. area of no grooves, cusps, fossae or ridges.
• The proximal surfaces are the ideal location.

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 Angulation of sprue former
• The sprue former is never directed towards thin cross sections of
the pattern. It should not be attached at 90o as it will create a
concavity in the mold wall, and eventually convexity in the
restoration. Also it creates turbulence within the mold cavity. The
sprue should be attached at an angle of 45o.

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 The sprue-wax pattern joint
• This should have a smooth uninterrupted surface.
• If high velocity ingress is required (due to rapid solidification, a
large mold etc.) the joint should be flared.
• If low velocity ingress is required (due to high viscosity of the
melt, slow escape of the gases etc.) the joint is made narrow or
constricted.
• The sprue former is attached with the help of sticky wax to
minimize stress release in the pattern.
• The flare shape at the junction insures the retention of the
sprue in the wax pattern.

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 Reservoir
• In cases, the diameter of the sprue is smaller than the average
cross sectional area of the pattern; some wax is added around the
sprue former 1-2 mm or as near as possible to the pattern sprue
junction in order to create an area in the mold that serves as
storage for molten metal so as to compensate for the localized
shrinkage porosity - called a reservoir.

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• It is always indicated when the sprue is
long and/or thin.
• The diameter of the reservoir should be
more than the average cross sectional area
of the pattern.
• When a reservoir is used, no intermediate
sprue should be interposed between it and
the wax pattern.
• Ideal flow into mold should be from thicker
portion to thinner section Q

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 Wax pattern removal
• The sprue former should be attached to the
wax pattern for removal. For a class II inlay, a
metal pin is attached on the marginal ridge
area
• The tip of the pin is heated and it is attached at
an angle of 45 degree with the help of low
fusing wax. Once the pattern is removed, the
sprue is thickened by addition of wax around
the pin. To obtain a hollow metal ring, a cut
syringe tip may be attached with the help of
the utility wax.
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For a class I inlay, it is attached to the
occlusal surface.
For MOD cavities, a Y shaped or a staple pin
sprue former is attached .

• diagram showing site of attachment

of sprue former.
• Arrow showing direction of removal.
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 Forming the crucible and
attaching the pattern
• The crucible part is funnel shaped and connected to the sprue such
that it should be bulkiest in cross section, flared and smooth.
• Crucible formers come readymade (rubber, metal or plastic), with
different sizes, diameters, and wall inclinations.

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Surface treatment of the wax pattern
• Casting waxes are hydrophobic in nature.
• They are difficult to wet with water and investment liquids.
• In order to capture the details, surface active agents (soaps) are
applied on the wax in order to allow wetting and intimate proximity.
• Also, vibration is used during flowing of the investment over the
pattern.
• Vacuum investment may also be performed.
• Q- advantages of vaccum mixing?
a. Porosities reduced
b. Increased tensile strength
c. Texture of cast is smooth

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• Q- what kind of burn out technique is used for plastic sprue?
Ans- 2 staged
• Q- indirect spruing
• Q- reservoir prevents?
• Q- why ring liners are placed?
• Q- how should the ring liner should ideally b placed?

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CASTING INVESTMENT AND
PROCEDURES

38
 What is investing ? What is disinvesting ?

Investment materials

Gypsum bonded Phosphate bonded Ethyl silicate

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 Q- What is sprue? And sprue former base?

Q- Refractory ?? Burn out ???

gypsum-based materials - gold alloy inlays, onlays, crowns, and larger

fixed dental prostheses (FDPs)

Phosphate-based investments - copings or frameworks for metalceramic

Prostheses

Ehyl silicate–bonded investment,- removable partial dentures made from

base metals (cobalt-based and nickel-based alloys

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Q- ADA specification for dental casting investment materials ?
Q- Type of investing material according to ADA/ANSI specification?

On basis of compensation of alloy shrinkage

Type I - compensate casting shrinkage primarily by thermal expansion

Type II - hygroscopic expansion
Type III- Removable partial denture with gold alloys

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 Gypsum bonded investment
• Composition-
1. Binder---- a-hemihydrate form of gypsum is generally the binder
2. Refractory – Silica
3. Modifiers
4. Coloring agent

1. Binder- Alpha hemihydrate is used.

gold-containing alloys with melting ranges below 1000 °C.
Problem ?? it shrinks considerably and occasionally fractures > 750
degrees
Q- Y not pure gypsum is used? (Ans- undersized castings)

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 a) 200 – 400 °C- slight contraction.

b) between 400 °C and

approximately 700 °C- A slight
expansion takes place

c) >700 - a large contraction then

occurs.

This later shrinkage is most likely

caused by decomposition
and the release of sulfur dioxide.

Problems- a) contamination of
nonoble castings

So should not be heated >700

degrees

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thermal expansion curves for the three common forms of gypsum products
Q- prefered agent of dental investment employed for gold casting contains all
except?
A) alpha hemihydrate
B) beta hemihydrate
C) quartz
D) Cristoballite

Q- thermal expansion curve sequence for gypsum products across temperature

200 to 700 degrees and above is?
Q- temperature beyond which gypsum should not be heated > 1292 º F

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2) Refractory – Silica
- To eliminate shrinkage caused by gypsum
Net expansion is required for casting – this will help in achieving this

Silica exists in at least four allotropic forms:

a)quartz, b) tridymite, c) cristoballite d) fused quartz

Q- Quartz and cristobalite forms are of particular dental interest

Q- inversion temperature-
•low” room-temperature crystal form, known as a quartz, to a “high” form.
α quartz  β quartz – 573 degree C with .45% linear expansion
α cristoballite  β cristoballite , 200- 270
Tridymite- 117 and 163 degree
45
Q- Beta form is stable above inversion
temperature only,
Q- Density of beta form is less whereas
volume is increased, thus cause
expansion
Q- Thus shrinkage of gypsum is
counterbalanced by silica.
Q- graphite is not a form of silica.
Q- which silica does not show
inversion?

46
• 3) MODIFIERS- modifying agents, coloring matter, and reducing
agents
• Ex – carbon and powdered copper (reducing agents)
• reducing agents are used in some investments to provide a
nonoxidizing atmosphere in the mold when a gold alloy is cast

• Some of the added modifiers—such as alkali-earth and transition-

metal chlorides, boric acid, and sodium chloride— not only regulate
the setting expansion and the setting time but also prevent most of
the shrinkage of gypsum when it is heated above 300 °C.
• In some instances, the modifiers are needed to regulate the setting
time and setting expansion, as described for the dental stones.

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Q- Setting time for dental inlay casting investment -
Ideally - should not be less than 5 or more than 25 minutes.
Usually – set initially in 9 to 18 minutes

Q- expansion-
a)Normal setting expansion
b)Hygroscopic setting expansion
c)Thermal expansion

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1. Normal setting expansion-
• should exhibit a maximum setting expansion in air of 0.6%.
• purpose of the setting expansion - enlarging the mold to compensate
partially for the casting shrinkage of the alloy.
• Typically, the setting expansion of these investments is approximately 0.4%

Variables-
Exothermic heat
Softer wax- more distortion ( that’s y type II inlay wax is used)

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• Hygroscopic setting expansion-
greater in magnitude than normal setting expansion, (6 times) (5 linear percent)
differs from normal setting expansion in that it occurs when the gypsum product
is allowed to set when placed in contact with heated water.
Q- used for casting of gold alloys
Q- Type II investments should exhibit a minimum setting expansion in water of
1.2%. The maximum expansion permitted is 2.2%.
Q- variables or factors affecting it-
A- silica ( directly proportional), finer particle size leads to more expansion,
alpha > beta hemihydrate
B- mixing time decrease  H.E decrease
C- older investment material  H.E decrease
D- greatest amount of hygroscopic setting expansion is observed if the
immersion takes place before the initial set.
E- higher W/P ratio - H.E decrease
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F- directly proportional to amount of water added
Q- At least 15% of binder is necessary to prevent drying shrinkage.

51
3) THERMAL EXPANSION OF GYPSUM-BONDED INVESTMENTS-
•when the quartz content of the investment is increased to 60%, with the
balance being the calcium sulfate hemihydrate binder, the initial
contraction of the gypsum is not eliminated.
•The contraction of the gypsum is entirely balanced when the quartz
content is increased to 75%.
The desired magnitude of the thermal expansion of a dental investment
depends on its use.
If the hygroscopic expansion is to be used to compensate for the
contraction of the gold alloy, as for the type II investments, thermal
expansion should be between 0% and 0.6% at 500 °C.
However, for type I investments, which rely principally on thermal
expansion for compensation, should not be less than 1% Or greater than
1.6%.
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• Strength-
Q- the compressive strength should not be unduly high ?
• The fracture resistance of the investment must be adequate to
prevent cracking, bulk fracture, or chipping of the mold during
heating and casting of gold alloys. Although a certain minimal
strength is necessary to prevent fracture of the investment mold
during casting.
• The strength of the investment is affected by –
• W/P ratio in the same manner as any other gypsum product;
• Heating the investment to 700 °C may increase or decrease the
strength as much as 65%, depending on the composition.
The greatest reduction in strength on heating is found in investments
containing sodium chloride.

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 Phosphate bonded investment
• COMPOSITION
The silica filler, typically 80% by weight, is in the form of cristobalite, quartz, or
a mixture of the two forms. The purpose of the filler is to provide thermal
shock resistance (refractoriness) and a high thermal expansion.

• The binder consists of magnesium oxide (basic) and a phosphate that is

acid in nature
• Originally phosphoric acid was used, but monoammonium phosphate has
replaced it.
• Colloidal silica suspensions in place of water are beneficial for mixing the
phosphate investments – better setting expansion

54
• Carbon is often added to the powder to produce clean castings and facilitate
the divesting of the casting from the investment mold.
• Appropriate when the casting alloy is gold, but there is disagreement
regarding the effects of carbon in phosphate bonded investment
• Palladium reacts with carbon at temperatures above 1504 °C
• Thus carbon free investment should be used in these cases

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 • Setting reaction-

product formed is the predominantly colloidal

multimolecular (NH4MgPO4.·6H2O) aggregate
around excess MgO and fillers.

On heating, the binder of the set investment

undergoes thermal reactions as suggested by
the following sequence

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• SETTING AND THERMAL EXPANSION –
• colloidal silica solution (sometimes called a special liquid) is used
instead of water.
• Slight expansion instead of contraction

57
• WORKING AND SETTING TIME
• Unlike gypsum investments, phosphate investments are markedly affected by
temperature.
• The warmer the mix, the faster it sets. (exothermic reaction).
• Increased mixing time and mixing efficiency, as determined by the type of mixer
and speed of mixing, result in a faster set and a greater rise in temperature.
• In general the more efficient the mixing, the better is the smoothness and
accuracy of the casting.
• The ideal technique is to mix as long as possible yet have just enough time for
investing.
• Mechanical mixing under vacuum is preferred.

• Q- all of following will cause alteration of setting time of phosphate bonded

investment material except?
• A. temp. B. L/P ratio, C. type of mixer D. type of alloy

58
• An increase in the L/P ratio increases the working time,
• Normal working time is very short (2 minutes or less) when the investment
is mixed at the manufacturer’s recommended L/P ratio at high speed (1750
rpm) for recommended time.
• Prolonged working time occurs at higher laboratory temperatures and also
when the liquid has not been chilled.

59
• SURFACE QUALITY OF CAST METALS
• Phosphate bonded investment- considered inferior to those gypsum-bonded
investment
• increasing the ratio of special liquid to water used for the mix markedly
enhances casting surface smoothness,
• it can lead to oversized extracoronal castings

60
 ETHYL SILICATE–BONDED
INVESTMENT
• binder is a silica gel that reverts to silica (cristobalite) on heating

a) pH of sodium silicate is lowered by the addition of an acid or an acid salt, a bonding

silicic acid gel forms.
MgO is added to strengthen the mix
b) An aqueous suspension of colloidal silica can also be converted to a gel by the addition
of an accelerator, such as ammonium chloride.

c) Another system for binder formation is based on ethyl silicate.

A colloidal silicic acid is first formed by hydrolysing ethyl silicate in the presence of
hydrochloric acid, ethyl alcohol, and water.
In its simplest form, the reaction can be expressed follows

polymer of ethyl silicate polysilicic acids

61
Q- Green shrinkage-
When a colloidal sol of polysilicic acid is mixed with quartz and cristoballite and
it is dried at 168 ºC, it forms a hard gel because of the loss of alcohol and water and a
volumetric shrinkage occurs known as green shrinkage.

•Gelation is likely to be slow and time-consuming.

•A faster method for the production of the silica gel can be used. Certain types
of amines can be added to the solution of ethyl silicate so that hydrolysis and
gelation occur simultaneously

•Investment can be heated to between 1090 °C and 1180 °C

62
 CLINICAL EVALUATION OF CASTING FIT

• Certainly a high degree of accuracy in marginal adaptation of 25 µm

or less Is required for all restorations.
• In one study- For “acceptable” restorations, the mean opening was
21 µm at the occlusal surface and 74 µm at the gingival region,
which is not as accessible visually. – in a inlay restoration

63
 COMPENSATION FOR
SOLIDIFICATION SHRINKAGE

Q- high heat technique of expansion?

•high temperature (650 °C to 700 °C) for gypsum-bonded investments
and up to 1050 °C for phosphate-bonded investments
•Normal setting expansion and hygroscopic expansion (low-heat)
method
• thermal expansion (high-heat) method.

64
• RINGLESS CASTING SYSTEM
• A ringless system that provides maximum expansion of investment
is available commercially.
• This system, called the PowerCast Ringless System (Whip-Mix
Corporation, Louisville, KY), consists of three sizes of rings and
formers, preformed wax sprues and shapes, investment powder,
and a special investment liquid.

65
 Preparation of master die

• Q- purpose of die ?
• most commonly used die materials are type IV (dental stone, high-strength)
and type V (dental stone, high-strength, high-expansion) improved stones
• chief disadvantage of the type IV gypsum die is its susceptibility to abrasion
during carving of the wax pattern.
• Gypsum dies are sometimes modified to
(1) make them more abrasion-resistant,
(2) change the dimensions of the dies,
(3) increase the refractoriness of the dies, or
(4) produce a combination of these effects.

Several means are used to increase the abrasion resistance, including –

silver plating, coating the surface with cyanoacrylate adhesive, and adding a
die hardener

66
• Non-gypsum die materials ?
• such as acrylic, polyester, and epoxy resins.
• These materials are limited in their compatibility with impression materials,
which would ordinarily be nonaqueous elastomers rather than hydrocolloid
or compound.
• Advantage – high abrasion resistance Q
• Disadvantage- slightly undersized in axial direction. Q

67
 Purpose of die spacer?

• The most common die spacers are resins.

• Although proprietary paint-on liquids are sold for this purpose, model paint,
colored nail polish, and thermoplastic polymers dissolved in volatile solvents
are also used.
• Such spacers are applied in several coats to within 0.5 mm of the
preparation finish line.

• Purpose-
1. to provide space for the cement luting agent
2. Make final cast slightly oversized for easier fit to ensure complete seating of
an otherwise precisely fitting casting or coping.
3. Act as a separator for the wax pattern from the die

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• Q - DIE STONE/INVESTMENT COMBINATION ?
• Q- divestment ?
• Ans- in this technique Die and the investment are made from
same material. Known as divestment.
• eliminate the possibility of distortion of the pattern on removal from
the die or during the setting of the investment

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• ELECTROFORMED DIES –
1. Metal dies
a) Copper plated dies
b) Silver plated dies
• electroplated impression material have-
a) moderately high strength,
b) adequate hardness, and
c) Excellent abrasion resistance.

Detail reproduction of a line 4 µm or less in width is readily attainable

on the resulting metal covered die when a nonaqueous elastomeric
impression material is used.

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• 1st step – Metallizing - Q
• to treat the surface of the impression material so that it conducts electricity.
• a thin layer of metal, such as silver powder, is deposited on the surface of
the impression material.
• metallizing agents are available, including bronzing powder and aqueous
suspensions of silver powder and powdered graphite

• 2nd step- silver cyanide bath immersion

Metallized Impression – cathode, silver plate- Anode
Q- direct current is applied for approximately 10 hours
Q- current- 5-10 mA/cm
Q- Hydrocolloid impressions are extremely difficult to electroplate, and the
process is not feasible for dental use.
Q- polysulfide rubber impressions are clinically acceptable when a silver
cyanide bath is used

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