CASTING PROCEDURES AND

DEFECTS

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 CONTENTS
• ✓Introduction
• ✓Steps of Casting Procedure
• ✓Various types of Casting Defects

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• • According to (GPT-9) the action of pouring or
injecting a flowable material into a refractory
mold.
• • The object formed is also referred to as “a
casting”.
• • There are various steps of fabrication of a
simple full metal crown.

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 Steps in Making a Cast Restoration
1. Tooth prepration
2. Impression
3. Die prepration
4. Wax pattern fabrication
5. Attachment of sprue former
6. Ring liner placement
7. Assembly of casting ring
8. Investing
9. Burn out or wax elimination
10. Casting
11. Sand blasting and recovery
12. Finishing and polishing
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 Tooth Preparation
• The tooth is prepared by the dentist to receive a cast
restorations.
• Care is taken to prevent undercuts that may prevent
seating.

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 Impression
• An accurate impression of the tooth is made usually with
elastomers.

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 Die Preparation
• A die is prepared from die stone or a suitable die
material or the impression is electroformed.

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 Die spacer

• A die spacer is coated or painted over the die which

provides space for the luting cement.
• The relief provided also improves seating of the
casting.

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 Wax pattern fabrication
• A pattern of final restoration is made with type II
Inlay wax or other casting waxes with all precautions
to avoid distortion.
• A die lubricant is applied before making the pattern
to help separate the wax pattern from the die.

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 Attachment of sprue former
• A sprue former is made of wax, plastic or metal.
• A reservoir is attached to the sprue or the
attachment of the sprue to the wax pattern is flared.
• The length of the sprue is adjusted so that the wax
pattern is approximately1/4” from the other end of
the ring.

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 FUNCTIONS OF SPRUE FORMER:-

 To form a mount for the wax pattern.

 To create a channel for the elimination of wax during
burnout.
 Forms a channel for entry of molten allloy during
casting.
 Provides a reservoir of molten metal which
compensates for alloy shrinkage during solidification.

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 Ring liner placement
• A ring liner is placed inside of the casting ring.
• Non asbestos ring liners like fibrous ceramic
aluminous silicate, cellulose or combination of both
can be used.

FUNCTIONS OF RING LINER:-

✓Allows for mold expansion(cushion effect)
✓Permit easy removal of the investment after casting.
✓It acts as a thermal insulator.

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 Investing
• Apply wetting on the wax pattern to reduce air
bubbles.
• Seat the casting ring into the crucible former taking
care it is located near the center of the ring.
• Mix the investment and vibrate.
• The ring is reseated on the crucible former and
placed on the vibrator and gradually filled with the
remaining investment.
• It is allowed to set for 1 hour

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Investing

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 Burn out or wax elimination
Purpose of burnout is
1. To eliminate the wax from the mold
2. To expand the mold (mold expansion)

Two stage burnout and expansion technique

✓ Ring is placed in a burnout furnace and heated to 400c in 20
minutes.
✓ Maintain it for 30 minutes.
✓ Over the next 30 minutes, temperature is raised to 700c and
maintained further for 30 minutes.

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 Single stage burnout and
expansion(Rapid
technique)

✓Followed only if patterns &

sprues are wax.
✓Place molds directly into
preheated oven at 700- 850c.
✓Hold for 30-40 minutes and
cast.

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 Casting
Various Casting machines are used
like:-
Based on method of casting
1. Centrifugal force type
2. Air pressure type
Based on heating system employed
1. Torch melted
2. Induction melted
3. Arc melted

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• Alloy is melted with a suitable heat source.
• When the alloy is molten it has a mirror-like
appearance and shifts like a ball of mercury.
• Hot casting ring is shifted from burnout
furnace to the casting machine.
• Arm is released and allowed to rotate which
creates a centrifugal force which forces the
liquid metal into the mold cavity

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• The arm is allowed to rotate till it comes to rest.
• The ring is allowed to cool for 10 minutes till the
glow of the metal disappears.
• We do Quenching for gold alloys. The ring is then
immersed in water which leaves the cast metal in an
annealed or softened condition.
• Metal ceramic and base metal alloys are not
quenched.

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 Sandblasting and Recovery
• Investment is removed and the casting is recovered.
• A pneumatic (compressed air driven) chisel is used to
remove the investment.
• Sandblasting is a process by which particles of an
abrasive(aluminium oxide) is projected at high
velocity using compressed air in a continuous stream.
• Casting is held in a sandblasting machine to clean the
remaining investment from its surface.

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 Pickling
• Surface oxides like black castings from the
casting are removed by pickling in 50%
hydrochloric acid.
• HCL is heated not boiled with the casting in it.

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 Finishing and Polishing
• Sprue is sectioned off with a cutting disc.
• Casting is trimmed, shaped & smoothed with suitable
burs & stones
• Minimum polishing is required if all the procedures
are followed meticulously.

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 DEFECTS IN CASTING
• A casting defect is an irregularity in the metal casting process
that is undesired.
• Errors in the procedure often results in defective castings.
• Defects in casting can be classified under four headings:-
1) Distortion
2) Surface roughness and irregularities
3) Porosity
4) Incomplete or missing detail

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