Spruing ,

Investing and
casting
DR. MAHMOUD N. ALMUGHANY

Curriculum :

Wax pattern construction .

Sprue ( Def, Role, Requirements and technique )

Casting ring and liner ( types, mold expansion )

Investment material (requirement, composition and

types )

Investing ( mixing and pouring )

Burn out

Casting ( Requirement, alloy melting, casting )

Quenching

Pickling

Divesting and finishing

Polishing

The process consists of surrounding the

wax pattern with a mold made of heatresistant investment material. eliminating
the wax by heating and then introducing
molten metal into the mold through a
channel called the sprue.

Wax Pattern Construction

Spruing

Sprue
Definition:

Its a channel through

which molten alloy can
reach the mold in an
invested ring after the wax
has been eliminated .

Role of a sprue :

Holds the wax pattern to avoid its distortion.

Creates a channel to allow the molten wax to

escape from the mold.

Enables the molten alloy to flow into the mold

which was previously occupied by the wax
pattern.

Sprue can made from : Metal , plastic and wax

Requirement of sprue :
Diameter
In general, a relatively large diameter sprue is
recommended because this improves the flow of
molten metal into the mold.
Molar around 2.5 mm ( 10 gauge), premolar 2 mm (12
gauge)

Reservoir :

Is a small amount of
additional wax
added to sprue
former 1 mm below
wax pattern .

Function :
to compensate for the
shrinkage occurs
during solidification
of the casting.

Reservoir

Location
The sprue should be attached to the
bulkiest noncritical part of the
pattern. away from margins and
occlusal contacts .
Normally, the largest nonfunctional
cusp is used.

Fuctional cusps :
Buccal cusps of the mandibular posteroir
teeth & Lingual cusps of the Maxillary
posterior teeth .

Attachment
Should be attached at angle to allow the incoming
molten metal to flow freely to all portions of the
mold, (About 45 degree ).

Length
The length of sprue former should keeps the wax
pattern 6 mm from the casting ring length to
Provides adequate bulk of investment to withstand
force.
Allows gases to escape from end of mold.
The pattern should be placed as possible to the
center of ring

Venting
Small auxiliary sprues or vents have
been recommended to improve
casting of thin patterns and may
helps in :
gases escape during casting.
compensate for the shrinkage during
solidification

Crucible Former
usually made of rubber, which serves as a
base for the casting ring during investing
and the sprue is attached to it .

The pattern is painted with surface tension reducer

and then carefully coated with vacuum-mixed
investment

Spruing technique

Direct
The flow of molten metal is
straight ( direct from casting
crucible to the pattern.

In Direct
Using aconnector or (runner
bar) which the wax pattern
sprue is attached .

Number of Sprues

Single

Double

Multiple

Casting
Ring and
Liner

Casting Ring
The

casting ring serves as a

container for the investment
while it sets and restricts the
setting expansion of the mold.

Types of ring according to

shape
Round
Oval

Complete
ring

Split ring

Rigid : Metal , plastic

Metal

Flexible: Rubber

plastic

Ring Liner :

Creates a space to allow for investment

expansion

Allow setting of investment material under water,

to give hygroscopic expansion

Regulate heat transfer through the investment

material.

Facilitate removal of investment from the casting

ring after casting.

Thickness of liner should be around 1 mm not less.

One or two layers.

3.0-mm short of both ends of ring will allow

supporting contact of investment with ring after
liner has burned out.

Material used as liner :

Asbestos liner

Cellulose liner ( paper )

Ceramic liner ( aluminum silicate )

Combination of ceramic and cellulose liner.

Four mechanisms to produce mold expansion:

Setting Expansion of Investment

Hygroscopic Expansion

Wax Pattern Expansion

Thermal Expansion

Setting Expansion

Occurs as a result of normal gypsum crystal growth in

air.
About 0.4% but partly restricted by metal investment
ring.

Hygroscopic Expansion

Max expansion: immerse investment-filled ring in

water bath at 38C.
Water in bath replaces water used by hydration
process space between growing crystals is
maintained crystals grow longer outward
expansion of mold.
About 1.2 to 2.2% max with expandable ring.

Wax Pattern Expansion

While investment is still fluid, expansion occurs when

wax is warmed above Temp at which it was
formed.

Thermal Expansion

when investment is heated in burnout oven.

Two purposes :

Investment
material

Requirements:

Precise reproduction of wax pattern.

Sufficient strength to withstand burnout

and casting.

Sufficiently porous to allow escape of

gases.

Expand enough to compensate

solidification shrinkage of alloy.

Composition of Investment

Refractory material or filler

Material that resist high temperature

Expand upon heating

Its problem have no cohesion to maintain the
shape of investment when dried

Binder
Mixed with filler to give some strength

Chemical modifier

Types:
Gypsum bonded
Phosphate bonded
Silica bonded

Gypsum Bonded Investments

use with alloys that melt below 1,000C.

Used with Type I, II, III gold alloys

Composition:

Phosphate Bonded Investments

Much stronger and can withstand much higher burnout temps
(800C +)
For alloys with casting temp > 1150C

Silicate Bonded Investments

base metal alloys such as chrom-cobalt and steel

The reason is that these alloys melt at temperatures ranging

from 1250 - 1400
A silica-bonded investment material can be heated up to
1200C

Investing

Technique
Hand mixing

Vacuum mixing

Vacuum mixing

Advantages :

Reduce the amount of porosity in the investment .

Texture of the surface casting is smoother with better
detail reproduction .
Compressive strength of the investment is increased .

Investment material
pouring
1- casting ring is filled up to its rim .
2- allow investment to set for about 1 hour .

3- crucible former is carefully removed .

Burn out

Wax Elimination

Wax elimination or burnout consists of heating the

investment in a thermostatically controlled
furnace until all traces of the wax are vaporized.

Once the investment is heated during the waxelimination procedure, heating must be
continued, and casting must be completed.
Bring the furnace to 200C (400F), and hold this
temperature for 30 minutes. Most of the wax is by
then eliminated.

Its advisable to begin the burn out procedure

while the mould is still wet because water
trapped in the pores of the investment reduces
the absorption of wax .

Burnout ovens

manual

semiautomatic

fully programmable
controls

Casting

Melting and casting

technique

Requires :
heat source : to melt the alloy
Casting force : to drive the alloy into the mould

Molten the alloy

Using Torch

Using electric furnace

Types of torch flame :

Gas air torch

Gas oxygen torch

Oxy- acetylene torch

Hydrogen oxygen generator

Types of torch tips :

Multi orifice

Single orifice

Flame zones :
(OXY- ACETYLENE flame)
1- Neutral Flame (Acetylene oxygen in equal
proportions)
2. Oxidizing Flame (Excess of oxygen)
3. Reducing Flame (Excess of acetylene)

Air pressure casting machine :

Alloy is melted in situ in crucible hollow of the ring ,

followed by applied air pressure on the melt

Centrifugal casting machine:

Alloy is melted in crucible , then forced in the mold

by centrifugal force .

Quenching

After the red glow has disappeared from

the button, the casting ring is plunged
under running cold water into a large
rubber mixing bowl

Pickling :
Surface of the casting appears dark with oxides and
tarnish. This surface film removed by these process
( pickling ) .
By place the casting in a dish and pour acid over it .
Heat the acid and dont boil it .

Type of acids :

Hydrochloric acid
Sulfuric acid

Ultrasonic devices

Divesting and Finishing

Polishing

Thank you