CASTINGPROCEDURES

DEFINITION

Castingcanbedefinedastheactofformingan
objectinamould

OBJECTIVES
1.Toheatthealloyasquicklyaspossibletoa
completelymoltencondition.

OBJECTIVES.
2.Topreventoxidationbyheatingthemetalwithawell
adjustedtorch.

OBJECTIVES.
3.Toproduceacastingwithsharpdetailsbyhaving
adequatepressuretothewellmeltedmetaltoforce
intothemold.

STEPS
1. Toothpreparation
2. Impression
3. Diepreparation
4. Waxpatternfabrication
5. Attachmentofsprueformer
6. Ringlinerplacement

STEPS.
7.Investing
8.Burnout
9.Casting
10.Recovery
11.Pickling
12.Polishing

TOOTHPREAPRATION

IMPRESSION

DIEPREPARATION

WAXPATTERNFABRICATION

SPRUE

RINGLINER

INVESTMENT

BURNOUT

CASTING

RECOVERY

POLISHING

DIEPREPARATION

DIEPREPARATION.
ADieisapositivereplicaofthepreparedtooth.
Fabricationofindirectwaxpattern.
Commonlyuseddiematerialsare
1.Dentalstone
2.Electroformeddies
3.Epoxyresins
4.Divestment

DIEPREPARATION.
Desirablequalitiesofdiematerials
1.
2.
3.
4.

Accuratereproduction
Dimensionalstability
Adequatestrength
Contrastingcolortothatofinlaywax

DIEPREPARATION.
DENTALSTONE
Advantages.
1. Goodreproduction
2. Dimensionalstability
3. Inexpensive
Disadvantages
1.Lackofabrasionresistance

DIEPREPARATION.
Electroformeddies
Advantages.
1. Betterreproduction
2. Goodstrength
Disadvantages
1. Timeconsumption
2. Expensive
3. Silvercyanide

DIEPREPARATION.
Epoxyresins
Advantages.
1. Bestreproduction
2. Goodresistancetoabrasion
Disadvantages.
1. Polymerizationshrinkage
2. Notcompatiblewithhydrocolloidimpression

DIEPREPARATION.
Divestment
Combinationofdiestoneandinvestment.Itisagypsum
basedmaterialwhichcanbeusedasthediematerialas
wellastheinvestingmedium.
Advantages.
1. Goodreproductionofdetails
2. Easeofuse
3. Compatiblewithmostimpressionmaterials
Disadvantages.
1.Notsuitableforhighfusingalloys.

WAXPATTERNFABRICATION

WAXPATTERNFABRICATION.
Directwaxpattern
Advantages.
1. Lesslabwork
2. Lessdiscrepancies
3. Lesstime
Disadvantages.
1. Moreskill

WAXPATTERNFABRICATION.
Indirectwaxpattern
Advantages.
1. Lesschairside time
2. Finishingandpolishingcanbedoneonthedie,
Disadvantages.
1. Morelabwork
2. Inaccuraciesofimpressionandcastresultsinerrors.

SPRUE

SPRUE.
The sprue former provides a channel for the molten
metal to flow into the mold space in an invested
casting ring after the wax pattern has been
eliminated.

SPRUE.
Types.
Thesprueformermaybemadeofwax,resinor
metal.
Waxandresinsprueformershavetheadvantageof
beingeliminatedduringburnout,sothereisnoneed
toremovethembeforecasting.

SPRUE.
Diameter.
Dependsuponthesizeofthewaxpattern,casting
machineandthetypeofalloy
Thesprueformerdiametershouldbegreaterthan
thethickestportionofthewaxpattern.

SPRUE.
Length.
The length should be such that the end of the wax
pattern is 3.25mm to 6.5mm away from the open
end of the casting ring.

SPRUE.
Attachment.
Thesprueformershouldbeattachedtothebulkiest
portionofthewaxpatterndueto..
1.Toreducetheresidualstressesinthewaxduring
attachment.
2.Toensuresupplyofmoltenmetaltofillallthinner
sectionsofthemould.

SPRUE.
Angulation.
Thesprueformershouldalwaysbeattachedatan
angleof45degreestothebulkiestportionofthe
pattern.Thiswillalloweasyandefficientflowofthe
moltenalloy.

SPRUE.
Reservoir.
Thisisformedbywaxaddedaroundthesprue
former(12mmfromthewaxpattern)
Toprovideaconstantsupplyofmoltenalloytofill
themoldspace.
Thealloyinthereservoirsolidifieslastafterthemold
spaceiscompletelyfilled.

INVESTMENT

INVESTMENT.
Castingringliner.
Inordertoallowmoreuniformsettingand
hygroscopicexpansionoftheinvestmentalineris
placedinsidethering.
Ceramicorcelluloselinersareused.
Thelineriskept3mmshortateachendofthering.

BURNOUT

BURNOUT.
Thespruebaseisremovedandthecastingringis
placedintheburnout.
1. Lowheattechnique(hygroscopictechnique)
500`c.
2. Highheattechnique(thermalexpansiontechnique)
700`c.

CASTING

CASTING.
1. Centrifugalcastingmachines.
2. Airpressurecastingmachines.

CASTINGDEFECTS
Defectsincastingscanbeclassifiedunderfour
headings:
1.Distortion
2.Surfaceroughnessandirregularities
3.Porosity
4.Incompleteormissingdetail.

I.DISTORTION
Anymarkeddistortionofthecastingisprobablyrelatedtoa
distortionofthewaxpattern
Thistypeofdistortioncanbeminimizedorpreventedto
propermanipulationofthewaxandhandlingofthe
pattern.
Somedistortionofthewaxpatternoccursasthe
investmenthardensaroundit.Thesettingand
hygroscopicexpansionsoftheinvestmentmayproduce
anunevenmovementofthewallsofthepattern.

Preventedby..,
1. Manipulationofwaxathightemperature
2. Investingpatternwithinonehourafterfinishing.

II.SURFACEROUGHNESS
Excessiveroughnessorirregularitiesnecessitate
additionalfinishingandpolishing
Preventaproperseatingofanotherwiseaccurate
casting.

II.SURFACEROUGHNESS.
AirBubbles. Smallnodulesonacastingarecausedby
airbubblesthatbecomeattachedtothepattern
duringorsubsequenttotheinvestingprocedure.
WaterFilms. Waxisrepellenttowater,andifthe
investmentbecomesseparatedfromthewaxpattern
insomemanner,awaterfilmmayformirregularly
overthesurface.Thistypeofsurfaceirregularity
appearsasminuteridgesorveinsonthesurface.

II.SURFACEROUGHNESS.
RapidHeatingRates. Itresultsinfinsorspinesonthe
casting.
Themoldshouldbeheatedgradually.
Thegreaterthebulkoftheinvestment,themoreslowly
itshouldbeheated.

II.SURFACEROUGHNESS.
Underheating. Incompleteeliminationofwaxresidues
mayoccuriftheheatingtimeistooshortorif
insufficientairisavailableinthefurnace.
Thecastingmaybecoveredwithatenaciouscarbon
coatingthatisvirtuallyimpossibletoremove

II.SURFACEROUGHNESS.
Liquid:PowderRatio. ThehighertheL:Pratiotherougher
thecasting.
ProlongedHeating.aprolongedheatingofthemoldatthe
castingtemperatureislikelytocauseadisintegrationof
theinvestment
Theproductsofdecompositionaresulfurcompoundsthat
maycontaminatethealloy.Suchcontaminationmaybe
thereasonthatthesurfaceofthecastingsometimes
doesnotrespondtoprickling.
Neverhigherthan700Candthecastingshouldbemade
immediately.

II.SURFACEROUGHNESS.
TemperatureoftheAlloy. Ifanalloyisheatedtotoo
highatemperaturebeforecasting,thesurfaceofthe
investmentislikelytobeattacked,andasurface
roughnessmayresult.
CastingPressure. Agaugepressureof0.10to0.14MPa
inanairpressurecastingmachineorthreetofour
turnsofthespringinanaveragetypeofcentrifugal
castingmachineissufficientforsmallcastings.

II.SURFACEROUGHNESS.
CompositionoftheInvestment. Theratioofthebinder
tothequartzinfluencesthesurfacetextureofthe
casting.Inaddition,acoarsesilicacausesasurface
roughness.
ForeignBodies.Whenforeignsubstancegetsintothe
mold,asurfaceroughnessmaybeproduced.

II.SURFACEROUGHNESS.
ImpactofMoltenAlloy. Thedirectionofthesprue
formershouldbesuchthatthemoltenalloydoes
NOTstrikeaweakpotionofthemoldsurface.
PatternPosition. Ifseveralpatternsareinvestedinthe
sameringtheyshouldnotbeplacedtooclose
together.

II.SURFACEROUGHNESS.
CarbonInclusions. Animproperlyadjustedtorch,ora
carboncontaininginvestment,canbeabsorbedby
thealloyduringcasting.

Surfaceroughnessandirregularities
AirBubbles.
WaterFilms.
RapidHeatingRates.
Underheating.
Liquid:PowderRatio.
ProlongedHeating.
TemperatureoftheAlloy.
CastingPressure.
CompositionoftheInvestment.
ForeignBodies.
ImpactofMoltenAlloy.
PatternPosition.
CarbonInclusions.

III.POROSITY
Porositiesinnoblemetalalloycastingsmaybe
classifiedasfollows:
1.Solidificationdefects
Localizedshrinkageporosity
Microporosity
2.Trappedgases
Pinholeporosity
Gasinclusions
Subsurfaceporosity
3.Residualair

III.POROSITY.
Localizedshrinkage isgenerallycausedbyincomplete
feedingofmoltenmetalduringsolidification.
Ifthespruefreezesinitscrosssectionbeforethis
feedingiscompletedtothecastingproper,a
localizedshrinkagevoidwilloccurinthelastportion
ofthecastingthatsolidifies.

III.POROSITY.
Localizedshrinkageporosity
Thistypeofvoidmayalsooccurexternally,usuallyin
theinteriorofacrownneartheareaofthesprue.
Theenteringmetalimpingesontothemoldsurfaceand
createsahigherlocalizedmoldtemperatureinthe
regionthatiscalledahotspot.
Thishotspotcausesthelocalregiontofreezelastand
resultinwhatiscalledsuckbackporosity

III.POROSITY.
Microporosity Thisprematuresolidificationcausesthe
porosityshownintheformofsmallirregularvoids.
Boththepinhole andthegasinclusion porosities are
relatedtotheentrapmentofgasduring
solidification.Botharecharacterizedbyaspherical
contour,buttheyaredecidedlydifferentinsize.
Thegasinclusionporositiesareusuallymuchlarger
thanpinholeporosity

III.POROSITY.
SubsurfaceporosityTheymaybecausedbythe
simultaneousnucleationofsolidgrainsandgas
bubblesatthefirstmomentthatthemetalfreezesat
themoldwalls.

III.POROSITY.
Entrappedairporosity ontheinnersurfaceofthe
casting,sometimesreferredtobackpressure
porosity,canproducelargeconcavedepressions.
Thisiscausedbytheinabilityoftheairinthemoldto
escapethroughtheporesintheinvestment.

IV.INCOMPLETECASTING
IncompleteCastingTheobviouscauseisthatthe
moltenalloyhasbeenprevented,insomemanner,
formcompletelyfillingthemold.

1.Distortion
2.Surfaceroughnessandirregularities
3.Porosity
4.Incompleteormissingdetail.

Surfaceroughnessandirregularities
AirBubbles.
WaterFilms.
RapidHeatingRates.
Underheating.
Liquid:PowderRatio.
ProlongedHeating.
TemperatureoftheAlloy.
CastingPressure.
CompositionoftheInvestment.
ForeignBodies.
ImpactofMoltenAlloy.
PatternPosition.
CarbonInclusions.

Porosity
Localizedshrinkageporosity
Suckbackporosity
Microporosity
Pinholeporosity
Gasinclusion porosities
Subsurfaceporosity
Entrappedairporosity