CASTING PROCEDURE

AND CASTING DEFECTS

Guided by, Presented by,

Dr. Jnanadev K R Chaithra Prabhu B
Mrs. Savitha P Rao 1st year post graduate
Department of Prosthodontics Department of Prosthodontics
 CONTENTS
 Introduction
 Definition
 Steps in casting
 Spruing
 Investing
 Wax elimination
 Casting
 Cleaning
 Finishing and
polishing
 Casting defects
 Alternative methods of
fabricating prosthesis
 Casting of titanium
 Conclusion
INTRODUCTION

W.H. Taggart
 DEFINITION

• CASTING :An object formed by the solidification of a

fluid that has been cast into a refractory mold

• CASTING :The action of pouring or injecting a flowable

material into a refractory mold
-GPT 9
STEPS IN CASTING PROCEDURE
 PKT INSTRUMENTS
WAX PATTERN
WAX PATTERN METHODS

DIRECT INDIRECT

TYPE 1 HARD TYPE 2 SOFT

INLAY WAX Shama bhat science of dental materials INLAY WAX
with clinical application 3ed
WAX PATTERN
REMOVAL

Contemprorary Fixed Prosthodontics

Rosensteil
 SPRUING

SPRUING: Attachment of the wax pattern to a conical base by

short extension of wax, plastic, or metal -Rudd & morrow vol2

• PURPOSE:
Escape of molten wax
Allow flow of molten metal
Act as reservoir
 TYPES

• Has rigidity • Stronger

wax

Plastic

metal
• Commonly
used of metal then wax
• Most • Minimum sprues
preferred distortion • Cannot be
• Easy to • May block burnout
manipulate the escape of removed
• Easy to burn wax with the
crucible
out
• Lacks
rigidity
VARIABLES & PRINCIPLES OF
OPTIMAL SPRUE DESIGN
FIVE General Principles

1. Sprue diameter
2. Sprue position
3. Sprue attachment
4. Sprue direction
5. Sprue length

Phillips science of dental materials 12th

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 Sprue diameter

• Same size as the thickest area of the wax pattern

Wax pattern Sprue diameter result

Small large distortion

large small Suck back

porosity

Phillips science of dental materials 12th

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Phillips science of dental materials 12th
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 Sprue position

• Can be attached

Occlusal surface

Proximal wall or just below the non-

functional cusp

Greatest bulk in the pattern – IDEAL

AREA

Phillips science of dental materials 12th

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Spruing of removable partial denture frame
work
 Sprue attachment
• The sprue’s point of attachment to the pattern should be
smooth to minimize Turbulence.

• Generally it must be Flared- Facilitating the entry of the

alloy.

direct Indirect

Gate
technique

Phillips science of dental materials 12th

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 Sprue direction

The sprue former is attached at

an angle 450 to allow the
molten metal to flow freely to all
the portions of the mold.

Should not be attached at right

angle-
• Turbulence
• Suck back porosity
• Casting forces may fracture the
investment
Phillips science of dental materials 12th
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 Sprue length

• Depends on the casting ring

• 6mm – Gypsum bonded investments
• 3-4mm –Phosphate bonded investments

• When sprue is to short-------far placed in the investment-----

leads to inadequate venting-----gases cannot be eliminated-----
leads to porosity

Phillips science of dental materials 12th

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 VENTING

• Small auxiliary sprue/vents are applied to improve casting of

thin patterns. Usually 18- gauges sprues are used.

• Act as heat sink and ensure escape of gases.

 RESERVOIR
• Small amount of wax added 1 mm away from

the junction of wax pattern and sprue

• Inserted to prevent localized shrinkage porosity.

• Because of its large mass of alloy and position in the heat

center of the ring, the reservoir remains molten to furnish
liquid alloy into the mold as it solidifies.

• The resultant solidification shrinkage occurs in the reservoir

bar and not in the prosthesis.
AIM : To compare various sprue designs with the conventional
sprue design

CONCLUSION
Within the experimental group, 4mm sprue was effective
compared to 3mm sprue diameter
No statistical significant results were seen among the
conventional and 4mm sprue design
 CASTING RINGS

• Serves as a container for the investment while it sets and

restricts the setting expansion of the mold
 CASTING RINGS

Split casting rings or plastic

casting rings are used to get
adequate lateral expansion
 RINGLESS SYSTEM
• With the use of higher strength, phosphate bonded
investments, the ring less technique has become quite
popular

• This method entails the use of a paper or plastic casting ring

and is designed to allow unrestricted expansion.

• Used for base metal alloys

Contemporary fixed prosthodontics

Rosenstiel 5th ed
 THE JOURNAL OF PROSTHETIC
DENTISTRY 2000

AIM: This study compared the vertical margin accuracy of lost

wax castings produced with the conventional casting technique
using a metal ring and a technique that uses a ring-less system.

CONCLUSION
The castings of the ring-less technique provided less vertical
margin discrepancy (mean value 181 ± 71 µm) than the castings
produced with the conventional metal ring technique (290 ± 87
µm and 291 ± 88 µm). The difference was significant (P<.001).
 CASTING RING LINER

• Lining----Most commonly used technique to provide

investment expansion

Ring liner

Asbestos Non asbestos

Allumino-silicate
cellulose
ceramic liner

Phillips science of dental materials 12th

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FUNCTIONS OF LINER

• To allow enough lateral expansion

• To reduce longitudinal expansion

• If wetted, these liners provide some extra water for

hygroscopic expansion mold

• Two or three layers give higher hygroscopic expansion of the

mold laterally
• To ensure uniform expansion, the liner has to be cut to fit the
inside diameter of the casting ring with no overlap.

• Liner can be used dry or wet

• If wet lining technique is used

Lined ring immersed in water and excess is shaken away
Squeezing the liner should be avoided [ variable amount of
water removal-----nonuniform expansion ]

Phillips science of dental materials 12th

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 Journal of International Society of Preventive
and Community Dentistry

GROUPS
AIM: To evaluate the effect of varying cellulose casting ring liner
GROUP
length andI- full
its length liner pre-wet
pre-wetting on theliningmarginal adaptation and
GROUP II-accuracy
dimensional full length
of liner dry lining
full veneer metal castings
GROUP III- 2mm short pre- wet lining
CONCLUSION:
GROUP IV- 2mm short dry lining
The
GROUP
dry cellulose
V- 6mm ringshortliners
pre wet
provided
lining better marginal adaptation in
comparison
GROUP VI-6mmto prewet
shortcellulose
dry liningring liners. Accurate cuspal height
was obtained with shorter ring liner in comparison to full‑length
cellulose ring liners.
 INVESTING PROCEDURE
• INVESTING: The process of covering or enveloping, wholly or in part,
an object such as denture, tooth, wax pattern etc., with a suitable
investment material before processing, soldering or casting.
-GPT 9

Various investment materials

1. Gypsum bonded investment

2. Phosphate bonded investment

3. Ethyl silicate bonded investment

Mixing procedure
 WAX ELIMINATION/ BURN OUT
Gold alloys 450 – 700 deg C
• WAX ELIMINATION : Removal of wax from the mold
usually by heat Ni/Cr alloys 700 – 900
-GPT 9 deg C
Co/Cr alloys 1000 deg C

BURN OUT

SLOW BURN RAPID BURN

OUT OUT
450 deg C 700 deg C
Applied dental materials John F
Mccabe 9th ed
POINTS TO CONSIDER

• Invested rings are placed in a room temperature furnace.

• Advisable to begin the procedure when the mold is still wet.

• The ring is placed in the furnace with the sprue hole facing
down.

• The burnout temperature is slowly increased in order to

eliminate the wax and water without cracking the investment.

Phillips science of dental materials 12th

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 Hygroscopic low heat technique

• Obtains compensation expansion from 3 sources.

1. 37°C water bath expands wax pattern.

2. Warm water entering the investment mold from top

adds some hygroscopic expansion.

3. Thermal expansion at 500°C provides needed thermal

expansion.

Phillips science of dental materials 12th

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ADVANTAGES:

1. Less investment degradation.

2. Cooler surface for smoother castings.
3. Convenience of placing molds directly in 500°C furnace.

DISADVANATAGE:
• Back pressure porosity great hazard in low heat technique.

Phillips science of dental materials 12th

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Standardized hygroscopic technique was developed for alloys
with high gold content; the newer noble alloy may require
slightly more expansion. This added expansion may be
obtained by making 1 or more of following changes.

1. Increasing water bath temperature to 40°C.

2. Using two layers of liners.
3. Increasing burnout temperature to a range of 600°C to
650°C.

Phillips science of dental materials 12th

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 High-heat thermal expansion technique

• Depend almost entirely on high-heat burnout to obtain the

required expansion, while at the same time eliminating the
wax pattern.

• Additional expansion results from:

1. Slight heating of gypsum investments on setting. Thus

expanding the wax pattern.

2. Water entering from wet liner adds a small amount of

hygroscopic expansion to the normal setting expansion.
Phillips science of dental materials 12th
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 CASTING
CRUCIBLES

4 types of casting crucibles are available :

1. Clay high noble-alloy.

2. Carbon high noble crown bridge , higher fusing , gold

based metal ceramic.

3. Quartz high melting range alloys and those that are

sensitive to carbon contamination.

4. Zirconia alumina.

Phillips science of dental materials 12th

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METHODS OF MELTING THE ALLOY

Dental Material And Their Selection

William J O'brien 3rd Ed
 TORCH MELTING

• Common for gold alloys

• Gas/ oxygen ------higher fusion temperature of gold alloys

intended for PFM and palladium alloys

• Air/ acetylene and oxygen/acetylene { hottest flame }

mixture generates higher temperature

Dental Material And Their Selection

William J O'brien 3rd Ed
Disadvantages

1. Excessive heat -----distils lower melting component ----

results in change in composition

2. Excessive heat------release of environmental gasses which

dissolves in molten metal and results in porous casting

3. Carbon contamination from acetylene flame---- brittle

castings

4. Excessive oxidation
Dental Material And Their Selection
William J O'brien 3rd Ed
Zones of torch flame

Phillips science of dental materials 12th

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 ELECTRIC MELTING

• Electric resistance melting, which is suitable for all gold

alloys, as well as

• Induction melting and Electric arc melting, which are

capable of melting cobalt-chromium and titanium alloys.

Dental Material And Their Selection

William J O'brien 3rd Ed
 CASTING MACHINE

• Casting
• A machines
very old provide
methodthe meansuses
which for transferring
steam the
pressure to drive the melt into the mold.
molten alloy from the melting crucible to the mold.
CASTING
• They all provide good castings when a
MACHINE
porous gypsum investment is used

PNEUMATIC CENTRIFUGA
FORCE L FORCE
CASTING MACHINES
 1. Torch Melting/Centrifugal casting
machine:
• Casting machine spring is first
wound from 2-5 turns

• Alloy is melted by torch flame in a

glazed ceramic crucible attached to
broken arm

• Spring is released

• Mold is casted by centrifugal force

Phillips science of dental materials 12th

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 2. Electrical resistance - heated
casting machine
• Alloy is melted electrically
by resistance heating.
• It is used to melt ceramic
alloys.
• Here the alloy is
automatically melted in
graphite or ceramic
crucible.
• The crucible in the furnace
is always against the
casting ring. So the alloy
remain molten slightly
longer and ensures
complete solidification.
 3. Induction Melting Machine

• The alloy is melted by an induction field that develops within

a crucible surrounded by water-cooled metal tubing.

• Commonly use for base metal alloys.

 4. Direct-current arc melting machine

• Direct current is produce between two electrodes: the alloys and

the water cooled tungsten electrode.

• Temperature between the arc rapidly increases to 4000°C – alloy

melts very quickly.

• High risk of over heating of the alloy.

• Damage may occur even after few seconds of over heating.

Phillips science of dental materials 12th

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 5. Vacuum or Air pressure casting
machines
• The alloy is heated to casting temperature and then drawn
into the evacuated mold by gravity or by vacuum and
subjected to additional pressure to force the alloy into the
mold

• For Titanium and Titanium alloys, vacuum arc heated argon

pressure casting machine is required.

Phillips science of dental materials 12th

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 CLEANING THE CASTING

After the casting has solidified the ring is removed and

quenched in water as soon as the button exhibits a dull red

glow.

Advantages

• The noble metal is left in annealed condition for burnishing,

polishing and similar procedure

• Aids in separating investment material

Clean residual investments on the casting

{ abrasive blasting }

PICKLING:

The surface of casting appears dark with oxide and tarnish.

Such a surface film can be removed by the process called

Pickling, which consist of heating the discolored casting in a

acid.
Method of pickling

• Place the casting in a test tube or dish and pour the heated
acid

PRECAUTIONS

• Not to boil

• Avoid using steel tongs ( galvanic cell )

• Avoid using contaminated acids

Pickling solutions

• 50% Hydrochloric acid--------gypsum bonded investment

Disadvantage
Fumes from the acid are likely to corrode the laboratory metal
furnishings
Health hazards

• Cold Hydrofluric acid

• 50% Hydrochloric acid or sulfuric acid + potassium

dichromate
• Gold based and palladium based metal ceramic and base
metal alloy are bench cooled to room temperature before
casting is removed from investment.

• Acid is NOT used for BASE METAL ALLOYS.

( REACTIVE)
FINISHING AND POLISHING

contemprorary fixed prosthodontics

Rosenstiel 5th ed
• Rubber, rag, or felt wheels impregnated with abrasives are
used in the initial stages of finishing. Final polishing is
accomplished with various oxides of tin and aluminum used
in conjunction with a small rag or chamois buffing wheel,
followed with an iron oxide rouge.
 CASTING DEFECTS

DISTORTION

SURFACE
INCOMPLETE CASTING ROUGHNESS &
OR MISSING DEFECTS IRREGULARITIE
DETAIL
S

POROSITY
 Change of shape
DISTORTION
• Careless removal of wax
• Marked
pattern distortion is related to distortion of wax pattern.
• Both change in shape and size causes misfit of the casting
• Too much vibration during
investment Change of size
• Too thick investment • Under or over
• Delay in investing compensation of casting
shrinkage
• Inhomogeneous setting and
thermal expansion of
investment
Science of dental materials V Shama
Bhat 2nd ed
 SURFACE ROUGHNESS,
IRREGULARITIES AND
DISCOLORATION

• Surface roughness defined as relatively finely spaced

surface imperfections whose height, width, and direction
establish the predominant surface pattern.

• Surface irregularities are isolated imperfections, such

as nodules that are not characteristic of the entire surface
area

phillip's science of dental materials

12th ed
Causes of surface roughness

• Rough wax pattern

• Coarse investment powder particles

• High water/powder ratio

• Insufficient wetting of wax pattern

• High casting force

Science of dental materials with clinical

application Shama Bhat 3rd ed
FINS

• Feather like thin extensions on the alloy casting surface

CAUSE
• Cracks in the investment
REASONS FOR CRACKS
• Weak investment
• High w/p ratio
• Improper mixing
• Prolonged heating
• Too high casting force

Science of dental materials with clinical

application Shama Bhat 3rd ed
 POROSITIES

• Most common among the defects

Solidification defects Trapped gases

Localized shrinkage Pin hole porosity

porosity
Microporosity Gas inclusion porosity

Suck back porosity Sub surface porosity

Back pressure porosity

phillip's science of dental materials
12th ed
 SOLIDIFICATION DEFECTS
PROBLEM LIKELY CAUSES REMEDIES
• Use of reservoir.
Localized shrinkage •Premature termination of
porosity flow of molten metal.
• Increase the sprue
•It mainly occurs at sprue- diameter
casting
junction.

Suck-back porosity •Hot spot created by hot •Flare the point of

metal impinging on point attachment of sprue.
on mold surface. •Lowering the casting
•It often occurs at Occluso temperature by about
axial Or incisoaxial line 30°C
angle

•Rapid solidification of the Increase the mold

Micro Porosity
Small Irregular mold or casting
•Casting temperature is too temperature
low
 TRAPPED GASES
• PROBLEM LIKELY CAUSES REMEDIES

Pin hole Porosity •poorly adjusted torch flame, or •Correctly adjusting

Small Spherical the use of the mixing or oxidizing and positioning the
zones torch during melting.

•Gas mechanically trapped •Prevent oxidation

by molten metal in mold. of alloys-Flux
Gas inclusion
•Gas incorporated during
Porosity
casting procedures.
Large Spherical
•Absorbed gases are expelled
on solidification.
•Rate of entering of
Sub Surface molten metal in mold.
•Simultaneous nucleation
Porosity
of solid grains and gas
bubbles
• Back Pressure •Inability of gases in mold •Proper venting.
Porosity to escape.
•Place pattern no more
•Pressure gradient that than 6-8mm from the
Displace air towards end
the end of of the casting ring
investment.

•Tendency for mold •Sufficient casting

to clog with pressure.
residual carbon.

•Proper burn out

temperature.
 INCOMPLETE CASTING

• This is due to :
-insufficient alloy .
-alloy not able to enter thin parts of the mold
-when the mold is not heated to adequately
-premature solidification of the alloy
-sprues blocked with foreign bodies
-back pressure of gases
-low casting pressure
 ALTERNATIVE TECHNOLOGY FOR
FABRICATING PROSTHESIS

• Sintering of burnished foil

• CAD CAM processing

• Copy milling

• Electroforming

• Three- dimensional printing

phillips science of dental materials 12th

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ELECTROFORMING

• The dies are duplicated with gypsum product that has high setting
expansion of 0.1% to 0.2%

• After a conductive silver layer is applied to its surface, the die is

connected to a plating head and then to a power source and placed
in a plating solution

• After a sufficient layer of metal is deposited, gypsum is removed

and coping is sandblasted

• Conventional way is used to build the ceramic layer

phillips science of dental materials 12th
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 SINTERING OF BURNISHED FOIL
• Commonly used commercial foil system------captek
• The system requires 3 pairs of materials to form composite
metal structure
1. Captek P & Captek G
2. Capcon & capfil
3. Captek repair paste & capfil

Consist of 88.2% of gold

9.0% of platinum group of metal
2.8% of silver

Coping is very thin, so minimum removal of tooth material,

hence better strength.
phillips science of dental materials 12th
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CAD CAM PROCESSING

• CAD CAM became available in 1980s for dental application

• Alternate method that can produce metal, ceramic or

composite restoration in one appointment

phillips science of dental materials 12th

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COPY MILLING

• Based on the principle of tracing the surface resin pattern

• Traced pattern is the replicated on a blank of ceramic,

composite or metal by grinding, cutting or milling by a
rotating wheel whose motion is controlled by a link through
the tracing device.

phillips science of dental materials 12th

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THREE-DIMENSIONAL PRINTING

• It is a form of additive manufacturing technology

• Stereolithography
• Direct laser metal sintering
• Electron beam melting

Phillips science of dental materials 12th

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 CASTING OF TITANIUM

 The high melting point of titanium (1670°C, murray, 1987);

the strong chemical affinity of titanium with gases such as
oxygen, hydrogen, and nitrogen;

 The high reducing ability of titanium;

 The unusually high solubility of some gases (oxygen, for

example) in titanium; and

 The relative low density of titanium.

 By combining the melting and casting techniques, four
different types of machines have been developed.

• A crucible with no
electrical conductivity • Tilting or split
• Two chambers
should be used. crucible
• Upper
• The( Cu Crucible)
casting and is
force
lower
created from the • One chamber which
• Arcdifferences
gas introduced
in the ingas houses parts for
both chambers
pressure melting and casting
• Temperature 6000 deg C • Before melting, the
chamber is evacuated
and then filled with
argon gas.
• Motor-driven casting
turntable that spins at
approximately 3000
rpm
CONCLUSION
REFERENCES

• Phillips science of dental materials 12th ed

• Craig’s dental materials 11th ed

• William J O’brien dental materials and their selection

• Science of dental materials with clinical application Shama

Bhat 3rd ed

• Rudd and Morrow dental laboratory procedure vol 2 & vol 3

CROSS REFERENCES

• Evaluation of the influence of the various sprue designs on the surface

porosity and dimensional accuracy of base metal alloy casting
NUJHS VOL 6 NO 4 DECEMBER 2016
• Dimensional accuracy of castings produced with ring-less and metal ring
investment systems
THE JOURNAL OF PROSTHETIC DENTISTRY JULY 2000
• The Effect of Casting Ring Liner Length and Prewetting on the Marginal
Adaptation and Dimensional Accuracy of Full Crown Castings
JOURNAL OF INTERNATIONAL SOCIETY OF PREVENTIVE AND
COMMUNITY DENTISTRY 2017
• The Use of Titanium in Dentistry Toru Okabe Baylor College of Dentistry,
Dallas Hakon Hero Scandinavian Institute of Dental Materials, Haslum
Thank you!