COMPARATIVE EVALUATION OF MARGINAL DISCREPANCY

AND SURFACE ROUGHNESS OF CAST COPINGS MADE BY

CONVENTIONAL AND ACCELERATED CASTING TECHNIQUES USING
TWO DIFFERENT PATTERN MATERIALS - AN INVITRO STUDY.
DISSERTATION SUBMITTED IN PARTIAL FULFILLMENT
FOR THE DEGREE OF MASTER OF DENTAL SURGERY (M.D.S)
TO
Dr. N.T.R UNIVERSITY OF HEALTH SCIENCES

NOVEMBER 2009 Dr.A.PREMALATHA
DEPARTMENT OF PROSTHODONTICS INCLUDING CROWN
AND BRIDGE AND IMPLANTOLOGY
NARAYANA DENTAL COLLEGE & HOSPITAL
BATCH: 2007-200
CERTIFICATE
This is to certify that the dissertation entitled !COMPARATIVE
EVALUATION OF MARGINAL DISCREPANCY AND SURFACE ROUGHNESS OF CAST
COPINGS MADE BY CONVENTIONAL AND ACCELERATED CASTING TECHNIQUES
USING TWO DIFFERENT PATTERN MATERIALS - AN INVITRO STUDY submitted for
the degree of Master of Dental Surgery "M.D.S# is a bonafide work carried out by DR.
A.PREMALATHA, during the period from 2007-2010 under our guidance and that this work has
not formed the award of any other degree, diploma, associateship, fellowship or other similar
titles.

DR.P.MA!S. MDS
"uide
Professor # $D, Dept of Prosthodontics
Principal, %arayana Dental &ollege
DR.P.SR'%'(AS RA$. MDS
&o)"uide
Professor, Dept of Prosthodontics
%arayana Dental &ollege.
Place * %ellore
Date * %o+ember ,--.

ENDORSEMENT BY
THE PRINCIPAL OF THE INSTITUTION
This is to certify that the dissertation entitled !COMPARATIVE EVALUATION OF
MARGINAL DISCREPANCY AND SURFACE ROUGHNESS OF CAST COPINGS MADE
BY CONVENTIONAL AND ACCELERATED CASTING TECHNIQUES USING TWO
DIFFERENT PATTERN MATERIALS - AN INVITRO STUDY is a bonafide research work
done by Dr. A. Premalatha under the guidance of Dr. P. Mahesh, Professor # $D, Department
of Prosthodontics including &rown and /ridge and 'mplantology.
Date: November 2009
Place: Nellore

Dr. P. MAHESH
Principal
Narayana Dental College & Hospital,
Nellore.
ACKNOWLEDGEMENTS
A journey is easier when you travel together. This dissertation work is
the result of many accompanied, supported and guided people. So it is a pleasant
aspect that I have the opportunity to express my gratitude for all of them.
I express my sincere indebtedness and heartfelt thanks to my guide, role model
teacher and excellent academician Dr..Mahesh MDS, rofessor and !ead,
"epartment of rosthodontics, #arayana "ental $ollege and !ospital, for his
constant support, encouragement and valuable guidance that enabled me
comprehend this dissertation and research and its successful culmination.
I sincerely express my deepest gratitude and humble thanks to my esteemed
teacher, Dr..Srinivas !ao MDS, rofessor, "epartment of rosthodontics,
#arayana "ental $ollege and !ospital, for his immeasurable encouragement,
unwavering guidance and constructive suggestions.
I would like to express my deepest gratitude to Dr.Dwara"anan#a Nai" MDS,
%eader, "epartment of rosthodontics, #arayana "ental $ollege and !ospital, for
his constant support and extreme help.
I would like to specially express my appreciations and sincere gratitude to
Dr.T.avan Ku$ar MDS, Sr. lecturer for his extreme support, help and valuable
suggestions. Iam also highly indebted to him for his help during the study in the
fabrication of die and preparing the samples.
I would like to express my heartfelt thanks to Dr.%.&.C.Ku$ar MDS' Sr. lecturer
for his constructive suggestions and precious ideas.
I express my heartfelt thanks to Dr. A. Su#heer MDS, Sr.&ecturer for his
appreciation, guidance and precious ideas.
Iam also thankful to Dr. %ijay Shan"ar (a#av ) Dr.D.%.%. %a$si"rishna MDS,
senior lecturers for their valuble support and guidance during my study period.
I sincerely express my gratitude to Dr.%.%a$si Krishna !e##y MDS, Sr.&ecturer
for his extreme help, support and timely suggestions.
I sincerely express my thanks to Mr. !avi Chan#ra' "epartment of #uclear
hysics, 'adras (niversity, $hennai, for doing the vertical marginal discrepancy
measurements in the study.
I express my deepest gratitude to Dr.O$"u$ar an# Mr.*alan' 'anufacturing
)ngineering "epartment, *nna (niversity, $hennai, for doing the surface roughness
measurements in the study.
I thank Mr.!. !avanan' +io,statistician for help to carryout the analysis of the
study.

I extend my gratitude to my batch mates, Dr. K. Shalini' Dr. K. Kiran Ku$ar
!e##y' my seniors Dr.%. %a$si Krishna !e##y' Dr. M. !e##i Narasi$ha !ao'
Dr. . Gautha$ and my loving -uniors, Dr.(.ManojKu$ar, Dr.M.Dhanala"sh$i,
Dr.K.Surya Narayana Murthy, Dr. *. Swa+na, Dr. C. Sa$eer Ku$ar !e##y, Dr.
M.Mahesh *a,u and without whom I would not have completed this work.
'y sincere special thanks to Dr.%.%a$si"rishna !e##y, my senior for his
cooperation during the study, guidance and precious ideas.
I thank all non,teaching staff of "epartment .f rosthodontics for their
assistance through the study.
&ast but not least, I express my heartfelt gratitude to all my family members
especially my husband Mr. M.*hara#waja, who supported through out my life, my
loving daughter M.Kusu$a Chow#ary' my dearest son M.%en"ata !a$arao
Chow#ary' my parents, mother in,law, father in,law, sister, brother, sister in laws,
who deserve the credit for what I am, and for all what I have achieved.

Dr. A.re$a latha.
CONTENTS
S .NO: CONTENTS PAGE
0 '%TR$D1&T'$% 0)2
, R!('!3 $4 5'T!RAT1R! 6),6
7 MAT!R'A5S # M!T$DS ,8)29
2 R!S15TS 2:)6.
6 D'S&1SS'$% 8-)8.
8 S1MMAR; # &$%&51S'$% 9-)9,
9 /'/5'$"RAP; 97)9:

LIST
OF TABLES
TABLE TITLE PAGE
Table 0
The results obtained in this study for the +ertical
marginal discrepancy along with the mean
estimated for each sample in the ")' techni<ue
calculated in microns =>?
2:
Table ,
The results obtained in this study for the +ertical
marginal discrepancy along with the mean
estimated for each sample in the ")'' techni<ue
calculated in microns =>?
2:
Table 7
The results obtained in this study for the +ertical
marginal discrepancy along with the mean
estimated for each sample in the ")''' techni<ue
calculated in microns =>?
2.
Table 2
The results obtained in this study for the +ertical
marginal discrepancy along with the mean
estimated for each sample in the ")'( techni<ue
calculated in microns =>?
2.
Table 6
The mean +ertical marginal discrepancy obtained
from basic mean +alues of four techni<ues =")',
")'',")''' # ")'(?
6,
Table 8
Test of significance for the mean +ertical marginal
discrepancy obtained from four techni<ues =")',
")'',")''' #")'(?
67
Table 9
The results obtained in this study for the surface
roughness along with the mean estimated for each
sample in the ")' techni<ue calculated in microns
=>?.
62
Table :
The results obtained in this study for the surface
roughness along with the mean estimated for each
sample in the ")'' techni<ue calculated in microns
=>?.
62
Table .
The results obtained in this study for the surface
roughness along with the mean estimated for each
sample in the ")''' techni<ue calculated in microns
=>?.
66
Table 0-
The results obtained in this study for the surface
roughness along with the mean estimated for each
sample in the ")'( techni<ue calculated in microns
=>?.
66
Table 00
The mean surface roughness obtained from basic
mean +alues of four techni<ues =")',")'',")''' #
")'(?
6:
LIST OF GRAPHS
GRAPH TITLE PAGE
"RAP 0
The basic data of +ertical marginal
discrepancy results obtained by ")'
techni<ue.
6-
"RAP ,
The basic data of +ertical marginal
discrepancy results obtained by ")''
techni<ue.
6-
"RAP 7
The basic data of +ertical marginal
discrepancy results obtained by ")'''
techni<ue.
60
"RAP 2
The basic data of +ertical marginal
discrepancy results obtained by ")'(
techni<ue.
60
"RAP 6
&omparison of the mean +ertical marginal
discrepancy obtained from basic mean
+alues of four techni<ues =")',")'',")'''
#")'(?
6,
"RAP 8
The basic data of surface roughness results
obtained by ")' techni<ue.
68
"RAP 9
The basic data of surface roughness results
obtained by ")'' techni<ue.
68
"RAP :
The basic data of surface roughness results
obtained by ")''' techni<ue.
69
"RAP .
The basic data of surface roughness results
obtained by ")'( techni<ue.
69
"RAP 0-
&omparison of the mean surface
roughness obtained from basic mean
+alues of four techni<ues =")',")'',")'''
#")'(?
6:
LIST OF FIGURES
FIGURE TITLE PAGE
FIG. A@ial +iew of custom made stainless steel former assembly =A?
and stainless steel master die =/?
78
FIG.2 $cclusal (iew of &ustom made stainless steel former assembly
=A? and stainless steel master die =/?
78
FIG.$ 5ine Diagram of custom) made stainless steel master die and
custom)made stainless steel former
79
FIG.% 5ine diagram of custom)made stainless steel master die #
stainless steel former in place. a. &ustom * made stainless steel
die. b. &ustom) made stainless steel former.
79
FIG.& A. Pattern Resin and /. 'nlay wa@ 7:
FIG.' 'n+estment powder # special 5i<uid 7:
FIG.7 %ickel * &hromium alloy 7:
FIG.(
Photo Microscope
7.
FIG.9 Surface Roughness analyAer 7.
FIG.0 Preparation of 'nlay 3a@ Pattern 2-
FIG. Preparation of Pattern Resin 2-
FIG.2 3a@ coping showing -.6mm thickness 2-
FIG.$ Pattern Resin coping showing -.6mm thickness 2-
FIG.% 3a@ Pattern Attached to crucible former 20
FIG.& Ring 5iner Placed 7mm short of Ring Margin 20
FIG.' 3a@ pattern in position in the casting ring 20
FIG.7 Di+ested casting 20
FIG.( &ast coping seated on the die 2,
FIG.9 Metal &oping showing -.6mm thickness 2,
FIG.20 Marginal gap of 72.-, at :-@ magnification by using photo
microscope of a cast coping obtained by con+entional casting
techni<ue employing three stage wa@ elimination
27
FIG.2 Marginal gap of 22.7. at :-@ magnification by using photo
microscope of a cast coping obtained by Accelerated casting
27
techni<ue employing single stage wa@ elimination
FIG.22 Marginal gap of 79.-8 at :-@ magnification by using photo
microscope of a cast coping obtained by con+entional casting
techni<ue employing three stage Resin elimination
22
FIG.2$ Marginal gap of 28.:8 at :-@ magnification by using photo
microscope of a cast coping obtained by Accelerated casting
techni<ue employing single stage Resin elimination
22
FIG.2% line diagram of custom made stainless steel coping holder 26
FIG.2& custom made stainless steel coping holder with coping 26
FIG.2' custom made stainless steel coping holder with coping on
surface roughness AnalyAer
26
FIG.27 surface roughness graph obtained by con+entional casting
techni<ue with three stage wa@ elimination
28
FIG.2( surface roughness graph obtained by Accelerated casting
techni<ue with single stage wa@ elimination
28
FIG.29 surface roughness graph obtained by con+entional casting
techni<ue with three stage Resin elimination
29
FIG.$0 surface roughness graph obtained by Accelerated casting
techni<ue with single stage Resin elimination
29

De#i-ate# to $y hus,an#
Mr. *&A!ADWA.A


/ntro#u-tion
The success of any cast restoration depends upon its fit on to the underlying tooth
structure.
0
The accuracy of the restoration is essential for its longe+ity, as it allows less pla<ue
accumulation at the marginal area pro+ides better mechanical properties, less cement space and
impro+es the esthetic result.
,,7
A deficient margin leads to pla<ue retention resulting in gingi+al
inflammation, marginal leakage which can lead to secondary caries, sensiti+ity, gingi+al
recession, cement dissolution and debonding of the restoration.
0,2,6
The marginal discrepancies of cast restorations are ine+itable, inspite of careful
attention to wa@ing, in+esting and casting procedures. !+en though published data on clinically
acceptable gaps +aries from 7->m to ,-->m, standard reference
8
on cast restorations mention a
marginal gap of up to 92>m is clinically acceptable. 't is one of the tasks of luting cements to
close these discrepancies. owe+er, cement will dissol+e rapidly under the margins if the
discrepancy is too large.
2
The rate of luting cement dissolution has been related empirically to the
degree of marginal opening. Thus, the larger the marginal discrepancy and subse<uent e@posure
of the dental luting cement to oral fluids the more rapid is the rate of cement dissolution. Sali+a
increasingly influences the dissolution of the cement if the marginal discrepancies are wider than
06->m.
2, 9
The obBecti+e of the casting process is to accurately reproduce a wa@ pattern. A
defecti+e casting results in a considerable loss of time and effort.
:
Types of defects in castings
ha+e been classified into 2 broad categoriesC
0. Distortion
,. Surface roughness and irregularities
7. Porosities
2. 'ncomplete or missing castings.
8, :
Surface roughness refers to finely spaced imperfections, of which the height,
width and direction establish the predominant surface pattern. The a+erage surface roughness of
castings made from noble alloy according to Pomes et al was in the order of -.98>m.
:
(arious
studies demonstrate that the surface roughness of as)cast gold alloy specimens ranged from
appro@imately , to 7->m on a+erage.
.
The surface roughness of dental castings is often greater
than that of the wa@ patterns from which they are cast. Surface roughness can be lessened by
abrading and polishing procedures, ensuring in this way a good tissue response to the alloy.
:
A
smooth surface not only pre+ents pla<ue and calculus accumulation, but it also impro+es the
corrosion resistance of the alloy. The surface roughness on the intaglio surface of the cast
restoration affects the fit of the restoration. Therefore, the smaller these flaws, the better the fit of
a restoration to the surface of the prepared tooth.
:
Se+eral implications are related to surface roughness of metal copings in P4MDs
especially in relation to adhesion. 'f the ceramic penetrates well and locks with the metal, it
pro+ides more room for chemical bonds to form there by increasing the ceramic *metal interface
bond. 'f the ceramic does not penetrate into the surface and +oids present on the interface it may
lead to bond failure and also compromise esthetics.
0-
There are a +ariety of factors that ha+e an important role in controlling surface
roughness and irregularities. These factors include the li<uid)powder ratio of the in+estment, air)
bubbles in the in+estment, water films, rapid heating rates, under heating, prolonged heating, the
temperature of the melting alloy, casting pressure, composition of the in+estment ,in+estment
techni<ue, foreign bodies, impact of molten alloy, carbon inclusions, and mi@ing and melting
different alloys together.
:
Eeeping this in mind, many materials and methods ha+e been suggested by +arious
authors to impro+e the fit, marginal accuracy and surface roughness of the casting. The marginal
fit and surface roughness is affected by the <uality of the preparation, the impression, the
working cast, the type and <uality of the wa@ used for the lost wa@ techni<ue, and by the
accuracy of the casting.
,
The accuracy of the casting is subBected to +olumetric changes occurring
due to shrinkage of wa@, resin and alloys. This shrinkage can be compensated by setting
e@pansion, hygroscopic and thermal e@pansion of the in+estment.
7
There ha+e been numerous reports, on attempts to perfect the casting procedures
by impro+ing in+estment materials and techni<ues.
,,7,.,00,0,
The maBority of these efforts deal with
so)called Fcon+entionalG in+esting and casting techni<ues, which usually re<uire at least 0 hour
bench set for the in+estment, followed by a one, two or three stage 'nlay 3a@ and Pattern Resin
elimination cycle as recommended by the manufacturer before the casting procedure.
8,.,0,,07
The
whole process is time consuming and re<uires appro@imately , to 2 hours for completion.
.,0,
The accelerated casting techni<ues ha+e been reported in an effort to achie+e
similar <uality results in significantly less time.
., 0,
The pattern is in+ested, cast and deli+ered in a
cost effecti+e, time sa+ing manner. This combination offers many ad+antages to the patient,
dentist, and dental laboratory technician, and has recei+ed increased attention as a method of
impro+ing producti+ity.
0,
Though studies
.,0,
ha+e reported that marginal discrepancies and
surface roughness by accelerated casting techni<ue are with in the clinically acceptable limits,
some studies
.,00,0,
ha+e reported that this procedure is techni<ue sensiti+e. Most of these studies
ha+e reported the effect of accelerated casting procedures on the fit of noble alloy castings.
owe+er, the effect of accelerated procedures on the marginal discrepancy and surface
roughness of base metal alloy restorations has not been ade<uately studied.
ence this in+itro study was conducted to measure and compare the +ertical
marginal discrepancy and surface roughness of base metal alloy cast copings made by
con+entional and accelerated casting techni<ues using 'nlay 3a@ and Pattern Resin.
The obBecti+es of this study included the followingC)
0. To e+aluate the +ertical marginal discrepancy of cast copings obtained by con+entional casting
techni<ue using 'nlay 3a@ and Pattern Resin.
,. To e+aluate the +ertical marginal discrepancy of cast copings obtained by accelerated casting
techni<ue using 'nlay 3a@ and Pattern Resin.
7. To compare the +ertical marginal discrepancy of cast copings obtained by con+entional and
accelerated casting techni<ue using 'nlay 3a@ and Pattern Resin.
2. To e+aluate the surface roughness of cast copings obtained by con+entional casting techni<ue
using 'nlay 3a@ and Pattern Resin.
6. To e+aluate the surface roughness of cast copings obtained by accelerated casting techni<ue
using 'nlay 3a@ and Pattern Resin.
8. To compare the surface roughness of cast copings obtained by con+entional and accelerated
casting techni<ue using 'nlay 3a@ and Pattern Resin.


!eview o0
literature
Coo!" #P !$ %& '1(7()
1*
e+aluated two phosphate)bonded in+estments and one
calcium sulfate in+estment for the surface smoothness and marginal fit they impart to gold
castings. A modified techni<ue was also e+aluated for each phosphate)bonded in+estment, where
the silica sol was not diluted and the spatulation time was reduced. The results of this study lead
to the following conclusionsC =0? The marginal fits obtained with all four phosphate)bonded
methods were comparable to each other and superior to that obtained with the calcium sulfate
in+estment. =,? The presence of nodules on the surface of the castings was more pre+alent with
the phosphate)bonded in+estments. owe+er, this effect was not statistically significant. =7?
&linical assessment of the roughness of the castings re+ealed that all the methods tested
produced clinically acceptable castings. =2? (isual obser+ation by fi+e dentists re+ealed that both
the recommended and modified techni<ues for one of the phosphate)bonded in+estments
=&eramigold? produced a smoother surface than any other in+estment tested. Rating of scanning
electron microscope photographs =H 8--? re+ealed no difference in the surface roughness
between any of the castings .&onse<uently, no definiti+e relation between in+estment type or
techni<ue and surface roughness was established. =6? %o correlation was demonstrated between
surface roughness, as e+aluated by either clinical obser+ation or scanning electron microscope
photography, and marginal fit of the castings.
N!+,% R- S%.,% AC '1(/0)
10
studied the setting reactions and thermal degradation of
the phosphate binders are interpreted from the DTA and H)ray diffraction data. The simple
chemical reaction has generally been shown to beC Mg$ I %
2

,
P$
2
J %
2
MgP$
2
.8
,
$.
owe+er, the setting reaction is in reality a more comple@ system of multi)molecular structure as
described herein. $n heating, the set product =%
2
MgP$
2
.8
,
$?
n
dehydrates to
=%
2
MgP$
2
.
,
$?
n
and subse<uently degrades into polymeric =Mg
,
P
,
-
9
?
n
K, crystalline Mg
,
P
,
-
9
L then the latter reacts with e@cess Mg$ present to form the final product, Mg
7
=P$
2
?
,.
D12% #D '1(/0)
13
studied nickel)chromium alloys as substitutes for gold alloys in
casting crown and bridge prostheses and found out more definiti+e research is needed on the
casting accuracy, finishing characteristics, porcelain)to)alloy bonding, and corrosion sensiti+ities
of these materials.
G%4!&+5 #.R. !$ %& '1(/1)
17
conducted his study to correlate margin design with the
seating and sealing of cemented full cast crowns under standardiAed, simulated clinical
conditions. The crowns were wa@ed on the steel dies, in+ested, and cast. The crowns were
cemented onto the Duralay dies and tested in an 'nstron testing machine. Measurements were
made of the cement thickness at the margin, shoulder, a@ial wall, and occlusal surface. The
cement thickness at the margin and occlusal surface were analyAed to find the amount of seal and
seat afforded by the +arious preparations. The .-)degree shoulder had a cement space of 89 > at
the margins. The 26)degree shoulder, shoulder with 7-)degree be+el, and shoulder with 26)
degree be+el followed, with spaces of .6, .., and 0-6 >, respecti+ely. 3ith regard to seating of
the restoration, the .-)degree full shoulder demonstrated the best seat, followed in order by the
26)degree shoulder, .-) degree shoulder with 26)degree be+el, featheredge, .-)degree shoulder
with 7-)degree be+el, chamfer with parallel be+el, and finally go)degree shoulder with parallel
be+el.
O61.% H !$ %& '1(/1)
1/
in+estigated si@ +ariables that could affect the surface roughness
of a casting. The +ariables were =0? type of alloy, =,? mold temperature, =7? metal casting
temperature, =2? casting machine, =6? sandblasting, and =8? location of each section. 't was
determined that the trailing portion of a complete cast crown had rougher surfaces than the
leading portion. igher mold and casting temperatures produced rougher castings, and this effect
was more pronounced in the case of the base metal alloy. Sandblasting reduced the roughness,
but produced scratched surfaces. Sandblasting had a more pronounced affect on the surface
roughness of the base metal alloy cast either at a higher mold temperature or metal casting
temperature.
D12% #D '1(/2)
1(
in+estigated the casting accuracy of four nickel)chromium alloys
=1ltratek, $mega, Microbond %MP
,
, and %obil)&eram? was compared to that of a precious alloy,
Nelenko F-G. The e@periment indicated that Nelenko F-G had the greatest casting accuracy,
followed successi+ely by 1ltratek, %obil)&eram, Microbond %MP
,
, and $mega. The following
conclusions may be drawn from this e@perimentC =0? The nickel)chromium alloys tested did not
cast as consistently or as accurately as precious alloy NelenkoF-G. =,? The casting accuracy may
be related to the amount of casting shrinkage that occurs in each alloy type, and further research
is necessary to determine if e@pansion compensation of the selected phosphate)bonded
in+estment recommended by the alloy manufacturers is ade<uate for the casting shrinkage of the
test alloys. =7? Alloy composition and techni<ue parameters may also influence the accuracy of
the casting, but further research is necessary to determine their singular effects.
L%2" AM !$ %& '1(/7)
20
in+estigated the related effects of =0? mi@ing rate, =,? ring liner
position, and =7? storage conditions on the setting e@pansion of both gypsum)bonded and
phosphate)bonded in+estment moldsL and subse<uently to correlate casting siAe with measured
e@pansion data. The results of these studies indicate the need for careful standardiAation of
in+esting and casting techni<ues if consistent results are to be e@pected. Results also re+eal that
the position and e@tent of ring liners, rates of mi@ing, and conditions of storage may be e+en
more significant in determining ultimate casting siAe than classically accepted factors such as
li<uidMpowder ratios or numbers of ring liners. The dynamic nature of setting e@pansion within
the first 8- minutes after mi@ing suggests that consistent results demand waiting at least that long
prior to burnout. 'f molds are to be stored o+ernight, ma@imum dimensional stability is probably
ensured by keeping them in 0--O relati+e humidity, particularly if &aS$
2
. ,
,
$)containing
gypsum)bonded in+estments are used.
V!.,+&"!% SG !$ %& '1(/7)
21
assessed the influence of three such in+estment
materials, &eramigold , and i)Temp &asting 'n+estment =3hip)Mi@ &orp., 5ouis+ille, Ey.?
and %eoloy i)eat &rown and /ridge 'n+estment =%eoloy Products, 'nc., Posen, '''.?, on the fit
of copings cast from fi+e base metal alloys =/iobond, Dentsply 'nternational, ;ork, Pa.L
&eramalloy '', &eramco, 'nc., !ast 3indsor, %. N.L 1nibond, 1nitek, 'nc., Monro+ia, &alif.L
/iocast, Neneric "old &o., 3allingford, &onn.L and %eobond '', %eoloy Products, 'nc.?. $+erall,
the fit of the test castings was poor. 'ndi+idual alloy)in+estment interaction appears to be
significant. Although marketed for use with base metal alloys, it appears that in+estment
manufacturersD recommended techni<ues re<uire alteration to enhance the fit of base metal
restorations.
M%.5%8 FA !$ %& '1(/*)
22
de+eloped a techni<ue to e+aluate setting e@pansion in
the pattern region of an in+estment mold. The +olumetric system pro+ides a method to ac<uire
information on setting e@pansion at the location of the wa@ pattern. 'nternally determined setting
e@pansion +alues do not agree with +alues deri+ed from e@ternal measurements =ADA trough
method?. Measurements obtained by the +olumetric method show less +ariability than those
obtained by the trough method. %o significant difference in +olume was seen between a
restricted metal ring and an unrestricted split rubber ring, which suggests a semisolid beha+ior of
the in+estment during the period of setting. The findings indicate a need to ree+aluate the
methods by which setting e@pansion is measured, as well as the mechanism by which the
e@pansion takes place. The need for further study by means of multiple (RSs or strain gauges
embedded in the in+estment is indicated, and in+estigation is currently in progress. The influence
of +ariously shaped casting rings and pattern position on resulting accuracy of the casting could
be determined by this method of in+estigation.
D!9,o HW '1(/0)
27
studied the marginal fit of full cast crowns made by
commercial dental laboratories with the design of the margin. 3hen cast restorations were made
by commercial dental laboratories, margins prepared with unbe+eled hea+y chamfers and
shoulders were most likely to ha+e openings that e@ceeded 7. >m on the dies. 1nbe+eled hea+y
chamfers and shoulders were also most likely to ha+e metal flash left on the margins. Enife)
edged and be+eled margins were least likely to ha+e metal flash or openings that e@ceeded 7.
>m on the dies.
S,+$: CD !$ %& '1(/0)
2*
in this study de+eloped a method for measuring the changes in
siAe and in marginal length of a complete crown wa@ pattern that occur during the casting
process. These +alues, combined with initial wa@ margin discrepancy, are used to calculate
marginal discrepancy +alues that are as accurate as the direct measurement of the same
discrepancy. This method is capable of measuring the effect of indi+idual +ariables on casting
siAe, marginal reproduction, and marginal discrepancy. The method is capable of determining
these +alues for o+ersiAed as well as undersiAed castings.
S2:8%.$; IS '1(/3)
20
re+iewed the methods and techni<ues to impro+e the fit of cast
restoration because the marginal fit of castings is one factor that leads directly or indirectly to
secondary caries, ad+erse pulpal reactions and periodontal disease. e found se+eral factors that
were necessary for good fit of the castings and some of them were percepti+e tooth preparation,
accurate impressions, precision castings and careful finishing procedures, but in addition to these
factors he reported that internal relief was basic for accurate marginal fit of the cemented
restorations.
A56%. < '1(//)
23
re+iewed casting metals in dentistry. 'n the literature, credit is gi+en to
Dr. Swasey =0:.-?, who introduced a techni<ue where a solid gold inlay could be prepared. 3a@
was used for making gold inlays for the first time by Martin =0:.0?. A few years later, Dr.
Philbrook =0:.8? introduced a pressure)casting method of producing gold inlays. About 0- years
later, Dr.Taggart =0.-9? presented a paper before the %ew ;ork $dontological "roup, in which
he discussed his casting techni<ue and machine. &astings made using TaggartKs casting machine
and his in+estment were generally too small and did not fit the ca+ities properly. (an orn
=0.0-? suggested and promoted the idea of thermally e@panding wa@ patterns prior to in+esting.
The de+elopment of cristobalite in+estment by &oleman and 3einstein in 0.,., who obtained a
1.S. patent a few years later =0.77?, as well as the introduction of the hygroscopic techni<ue
=Scheu, 0.7,?, were responsible for the greatest impro+ement in the fit of dental castings. 4rom
the time that Dr. Scheu introduced his hygroscopic techni<ue, +arious aspects of hygroscopic
in+estments were studied by many indi+iduals, and some theories were postulated. 4inally,
Mahler and Ady =0.8-?, in their classic paper, showed that the hygroscopic e@pansion of dental
in+estments is a continuation of setting e@pansion and proposed the theory which is accepted
today. The <uality of dental castings would not be where it is today if a better understanding of
the basic nature of dental castings and impro+ement in in+estments and alloys had not been
accomplished. Much work in the +arious aspects of dental casting techni<ues P such as the
effect of mold and metal temperature on the fit of castings, castability of the +arious alloys,
choice of sprue as well as its siAe and location, and the effects of +arious types of dental wa@ on
the resultant casting P has been reported.
Ho&,!5 #R !$ %& '1(/()
0
inferred that the measurements of misfit at different
locations are geometrically related to each other and defined as internal gap, marginal gap,
+ertical marginal discrepancy, horiAontal marginal discrepancy, o+ere@tended margin, under
e@tended margin, absolute marginal discrepancy, and seating discrepancy. The significance and
difference in magnitude of different locations are presented. The best alternati+e is perhaps the
absolute marginal discrepancy, which would always be the largest measurement of error at the
margin and would reflect the total misfit at that point.
H1$!. A#- H1$!. AR '1((0)
27
in this re+iew stated that there is +ariation regarding
the ma@imum acceptable marginal discrepancy, there is little argument that poorly fitting
margins are a fre<uent finding. 5arge discrepancies are clinically significant, since they facilitate
pla<ue retention. Margins incorporating slip Boint geometry ha+e usually been fa+ored as a
method of minimiAing seating and sealing discrepancies. owe+er, many of these discussions
largely ignored the effects of the cementing medium and the clinical applicability of slip Boint
geometry is based on <uestionable assumptions with regard to casting accuracy and seating.
"reater understanding of the role of restorati+e margins and gingi+al health indicates the need
for shallow margin placement within the cre+ice, which re<uires a reassessment of the use of
long be+els. oriAontal margins can be made accurately and, when combined with procedures to
ma@imiAe crown seating, may pro+ide the best method of minimiAing seating discrepancies and
ma@imiAing gingi+al health.
F!&$o DA !$ %& '1((1)
2/
e+aluated the relationship between marginal adaptation
of dental castings and periodontal tissue health <uantitati+ely. 4orty)two crown restorations in ,.
randomly selected patients were selected for this study using three criteria. =0? The crowns were
placed at the 1ni+ersity $f %orth &arolina School $f DentistryL =,? the crowns were in ser+ice
for a minimum of 2 yearsL and =7? the crown margins were within the intracre+icular cre+ice
=subgingi+al?. Replica impressions of the facial margins of specific crowns were made with a
+inyl polysilo@ane impression material, and poured casts were prepared for scanning electron
micrograph e+aluation. Marginal discrepancy measurements were identified on each micrograph
at 0- e<ually spaced locations along the margin and a+eraged for each specimen. Periodontal
indices of pocket depths, cre+icular fluid +olume, and gingi+al inde@ were accumulated for
clinical measurements. Pearson correlation and /onferroni adBusted probability tests were
performed, but no significant correlation was found between marginal discrepancy =-.08 Q -.07
mm? and pocket depth =,.2 Q -.. mm?. owe+er, a strong correlation =p R -.--0? e@isted
between marginal discrepancy and gingi+al inde@ =, Q -.:? and between marginal discrepancies
and cre+icular fluid +olume =2... Q 70.0?. These results established that a significant <uantitati+e
relationship e@isted between the marginal discrepancy and periodontal tissue inflammation for
subgingi+ally located crown margins.
#%2o=5 MS !$ %& '1((1)
2(
in+estigated the rate of type ' Ainc phosphate cement
solubility as it relates to the degree of marginal opening. StandardiAed test samples were
constructed that would simulate clinically rele+ant marginal gaps of ,6, 6-, 96, and 06- microns
and their subse<uent cement lines. The study was di+ided into two phases. Phase 0 e+aluated the
effects of simple diffusion on cement solubility in a static en+ironment, whereas phase ,
in+estigated the effects of con+ecti+e forces on cement dissolution in a dynamic en+ironment.
/oth the phase 0 and phase , studies demonstrated no significant difference in the rate of cement
dissolution for the ,6), 6-), and 96)micron test groups. The 06-)micron test groups for both and
phase , studies should not be compared because different methodologies were used.
C%,>%6+ WV !$ %& '1((7)
70
study compares an accelerated techni<ue for the casting
of post)and)core restorations with four traditional techni<ues. The accelerated techni<ue uses two
phosphate)bonded in+estments and the traditional techni<ues use gypsum) and a phosphate)
bonded in+estment. The study measures and compares the differences between the seating of the
casting and the seating of the acrylic resin pattern. The seating of the patterns after 7 months of
storage was consistently worse than the ,)week measurements of fit. The ferrule and nonferrule
patterns were not statistically different in seating. Measurement of the castings showed that the
ferruled castings seated significantly worse than the nonferrule castings. The difference in the
seating of the castings as compared with the patterns was considered clinically unacceptable,
showing a range of -.7-0 mm t o -.6,: mm. The nonferrule castings showed a significant
difference in seating among groups. The difference ranged from )-.-.. mm to -.7,, mm. The
effects of the techni<ues on the fit of castings with and without a ferrule are also compared. The
castings of the ferrule subgroups were considered clinically unacceptable and were not analyAed
for significance. Among the nonferrule castings, the group using a gypsum in+estment and
con+entional techni<ue for in+esting and burnout but no ring liner showed the best seating. The
accelerated techni<ue was intermediate in seating with a difference of -.02: mm from the seating
of the patterns. This group was significantly different from the two best groups but not from the
remaining three groups.
H1$$o #E M%.5:%&& GW '1((7)
71
in this study determined whether three
different phosphate bonded in+estments could pro+ide ade<uate e@pansion to compensate for the
casting shrinkage of AgPd. The in+estments were mi@ed with distilled water or their uni<ue
special li<uids pro+ided by the manufacturers and allowed setting times of 0 hour or ,2 hours.
Setting e@pansions were measured with a +ertical dilatometer. 3hen mi@ed with special li<uid,
material ' had a mean setting =0 hour? e@pansion of -.0.O Q -.-0OL material '', -.02O Q -.-7OL
and material ''', 0.09O Q -.-:O. Twenty)four hours of setting did not significantly increase the
setting e@pansion =p S -.-6?. Mi@ing the three in+estments with distilled water drastically
reduced setting e@pansions. A three)way analysis of +ariance was computed to e+aluate the data
and in+estigate significant interacti+e and main effects. The two)way interaction =material @
li<uid? was significant. The results were consistent with the concept of a higher silica)containing
special li<uid for material ''' compared with the other materials.
B%+&!" #H- S:!..%.9 D# '1((*)
72
study determined the mean time inter+al from
start of mi@ing to the ma@imum e@othermic setting reaction temperature for each in+estment. A
chromelMalumel thermocouple was placed at the heat center of a methylcellulose lined casting
ring, using wet or dry ring liner. 'n+estments were +acuum mi@ed at the recommended ratio for
the accelerated techni<ue. &olloidal silica solution and dd
,
$ were combined at a 6-C6- ratio to
meet the manufacturerKs recommended li<uid +olume. Part two determined the dimensional
reproduction of a standardiAed pattern and its casting using both casting techni<ues. Mi@ing
ratios were the same as in part one for the accelerated techni<ue and 96O colloidal silica to ,6O
double)distilled water =dd
,
-? for the con+entional techni<ue. The accelerated techni<ue used
the mean setting time established in part one followed by a 06)minute furnace holding time at
9,6T& =076-T4?. The con+entional techni<ue used a ')hour bench setting time, followed by
placing the mold into a cold furnace. A controlled rate of climb to a ma@imum temperature of
9,6T& =076-T4? was used with a ')hour soak time. !ach pattern and its casting were measured at
four sitesC =0? 5ength of the post)and)core assembly, =,? ma@imum core diameter, =7? post
diameter at the core base, and =2? post diameter at its ape@. A significant difference was found
between the time inter+al to ma@imum e@othermic setting reaction temperature for all the
in+estments (P R .-0?. The accelerated techni<ue produced castings with a relati+e dimensional
increase of -.00O to 2.:-O. The con+entional techni<ue ranged from a -.-2O decrease in siAe to
an increase of 7.86O. &astings made with the accelerated techni<ue were significantly different
than those made with the con+entional techni<ue (P R .-0? Differences in the time inter+al to
ma@imum e@othermic setting reaction temperature indicate that each phosphate in+estment
should ha+e a recommended setting time before introduction into the furnace. The carbon)
containing in+estment showed the least relati+e change of the three in+estments e+aluated for
both casting techni<ues.
S2:!+9!. RL '1((*)
77
in+estigated an accelerated method of using a light)cured
acrylic resin and rapid burnout for casting a direct)pattern post and core restoration. 5ight)cured
acrylic resins are an alternati+e to chemically cured acrylic resins or indirect patterns formed
from an elastomeric impression. The procedure can eliminate an appointment for the patient in
the fabrication of the post and core restoration and can be completed in most dental offices with
minimal laboratory facilities. &hair)side time is sa+ed because of the elimination of one
pro+isional restoration when two are usually re<uired. 5aboratory time is also sa+ed because of
the decrease in in+estment setting and burnout time.
I6&!5+%5 A !$ %& '1((3)
7*
compared the marginal fit of M$D inlay and full)crown
patterns fabricated from wa@, autopolymeriAed acrylic resin, and two light)polymeriAed,
diacrylate resin pattern materials on standardiAed dies. 4or the M$D inlay patterns, marginal
gaps ranged from 9 to ,7 >m, and the light)polymeriAed, diacrylate resins and autopolymeriAed
acrylic resin material had statistically smaller gaps than the inlay wa@. 4or the full)crown
patterns, marginal gaps ranged from 0- to ,7 >m, with the e@ception of the autopolymeriAed
acrylic resin prepared by the bulk techni<ue =2- to 28 >m?. 3ith the incremental techni<ue, the
light)polymeriAed, diacrylate resins and inlay wa@ had statistically smaller gaps than the
autopolymeriAed acrylic resin material. $+erall, the incremental techni<ue produced e<ual or
smaller marginal gaps than the bulk techni<ue for full)crown patterns. "enerally, the patterns
measured at 0 hour had smaller marginal gaps than at ,2 hours. 3hen measured on intra) and
e@tracoronal master dies, the light)polymeriAed, diacrylate resins had e<ual or better marginal fit,
compared with wa@ or autopolymeriAed acrylic resin, and were less affected by placement
techni<ue and storage. The marginal gaps of all four pattern materials ranged from 9 to 28 >m
and are within the range of clinical acceptability.
I$o M !$ %& '1((3)
70
e+aluated the relationship between flow characteristics,
bending strength, and softening temperature of paraffin and dental inlay wa@es to casting
shrinkage when patterns were in+ested with a phosphate)bonded in+estment. This study found
that the casting shrinkage decreased as the flow of the wa@ pattern increased. The flow of the
wa@ pattern increased as the e@othermic reaction increased. A larger casting ring is suggested for
castings when a relati+ely thick wa@ pattern or an inlay wa@ that has a high strength, softening
temperature, and low flow percentage is used. 3hen wa@ patterns are formed for cast
restorations, it is important to select the type of wa@ with the most desirable properties for the
margin and the occlusal portions. Moreo+er, to accurately fabricate castings, it is necessary to
understand the physical properties of the chosen wa@es.
E%.5:%8 R !$ %& '1((7)
73
'n an earlier in+estigation, it was shown that when
full crowns are cast in gypsum)bonded in+estments, their relati+e inaccuracy is affected by both
the in+estmentKs potential e@pansion and its hot strength. This study repeated the earlier one, but
used a high)melting gold alloy and two phosphate)bonded in+estments. The in+estments were
used under conditions which ga+e a range of potential e@pansions and hot strengths. &asting
inaccuracies were determined both diametrally and a@ially. All castings showed distortion, which
+aried under the different conditions. All were o+ersiAed a@ially, by amounts +arying from
I-.:O to I,.7O. Diametral inaccuracies ranged from )-.,O to I -.9O. 'n+estment e@pansion
had a strong effect on a@ial inaccuracy, but a negligible effect on diametral inaccuracy.
&on+ersely, hot strength had a strong effect on diametral inaccuracy, but only a +ery weak effect
on a@ial inaccuracy. 3ith phosphate)bonded in+estments, both potential e@pansion and hot
strength are important parameters of relati+e casting inaccuracy. 'n combination, these properties
showed +ery strong correlations with both diametral and a@ial inaccuracies. The obser+ed
distortions were the result of anisotropic mould e@pansion and anisotropic alloy shrinkage. The
best fit, and least distortion, occurred with an in+estment setting under dry conditions.
<o5$%$o1&%?+5 E !$ %& '1((/)
(
e+aluated the marginal fit and surface roughness of
complete crowns made with a con+entional and an accelerated casting techni<ue, and found out
no statistical difference in the marginal discrepancy of cast crowns made by using accelerated
techni<ue as compared with con+entional techni<ue. There was no difference in the a+erage
surface roughness of cast crowns between the accelerated and the con+entional techni<ues.
&linically acceptable complete castings can be obtained with the accelerated techni<ue if
optimum heating conditions are selected for each in+estment. Therefore they concluded that the
accelerated casting techni<ue described in this study could be a +ital alternati+e to the time)
consuming con+entional techni<ue.
S2:+&&+6 ER !$ %& '1((()
12
measured the marginal gap and determined the clinical
acceptability of single castings in+ested in a phosphate)bonded in+estment with the use of
con+entional and accelerated methods. The following conclusions were drawn from this studyC
=0? Marginal gaps for castings made with an accelerated techni<ue showed no statistical
difference when compared with a con+entional casting group. =,? The accelerated casting
techni<ue offers a cost effecti+e and time)sa+ing method by which single)unit castings for
metalMceramic crowns can be fabricated. =7? The methods used for accelerating the casting
process are techni<ue sensiti+e. Minor +ariations in the procedures can cause casting defects
such as nodules, fins, and porosity. Repeated use of the accelerated techni<ue can pro+ide the
dental laboratory technician with predictable, clinically acceptable castings for metalMceramic
crowns.
B&%2?,% RB '2000)
11
This pilot study in+estigated the effect of , rapid mold
preparation schedules on full crown castings by comparing siAe, margin sharpness, and surface
roughness. Three groups of 0- crowns were cast with a type ''' gold alloy. All crowns were
nominally identical, only their mold preparation schedules differed. Two groups used accelerated
schedulesL the third group was cast using a con+entional schedule. "roup comparisons were
based on direct microscopic measurements of crown diameters =U6- magnification?, and surface
roughness was measured. Margin sharpness was Budged by amount of marginal length lost in the
a@ial direction as a result of the casting process. &rowns were successfully cast using accelerated
mold preparation techni<ues and considerable time was sa+ed, but a small loss of margin length
or fineness was obser+ed.
C%5$+&&o RD !$ %& '2000)
77
e+aluated the influence ofC =0? a cellulose ring liner,
and =,? a lower casting temperature of the metal ring, on the dimensions of a cast post.
!@perimental posts were measured before and after casting to determine the effect of ring liner
and casting ring temperature on the dimensional beha+ior of a phosphate)bonded in+estment
material. 3ithin the limits of this study, it was found that decreasing the casting ring temperature
from :06T& to 8--T&, along with the absence of a ring liner, produced undersiAed cast posts. A
slightly undersiAed cast post may be easier to fit and cement in the prepared root canal, and thus
decrease chairside time.
G.o$! M !$ %& '2000)
7/
in this study estimated the minimum number of gap
measurements on margins of single crowns to produce rele+ant results for gap analysis. Ten all)
ceramic crowns were fabricated on a master steel die. "aps along crown margins were
in+estigated in a scanning electron microscope on the master steel die without cementation and
on replica dies after con+entional cementation. Measurements were made in 0-- >m steps
according to 7 gap definitions. The initial number of measurements per crown =n J ,7-? was
reduced to smaller subsets using both systematic and random approaches to determine the impact
on the <uality of results. $n the data of gap definition 0, reduction from ,7- to about 6-
measurements caused less than Q6 >m +ariability for arithmetic means. Analysis of standard
errors showed slowly increasing +alues smaller than 7 >m, both indicating no rele+ant impact on
the <uality of results. Smaller data siAes yielded accelerated increase of standard errors and
di+ergent +ariabilities of mean. The minimum of 6- measurements did not depend on gap
definition or on cementation condition. 4ifty measurements are re<uired for clinically rele+ant
information about gap siAe regardless of whether the measurement sites are selected in a
systematic or random manner, which is far more than what current in +itro studies use.
Lo,=%.9%5 P !$ %& '2000)
2
compared the +ertical margin accuracy of lost wa@
castings produced with the con+entional casting techni<ue using a metal ring and a techni<ue
that uses a ringless system. The following conclusions were drawnC =0? The +ertical margin
discrepancy of the ringless group for the buccal, the lingual, and the distal sites were
significantly less than that of the , ring groups =PR.--0?. =,? There was no significant difference
of the +ertical margin discrepancy between the , metal ring groups. =7? There was no significant
difference in the +ertical margin discrepancy at the buccal, lingual, mesial, and distal surfaces
within the same group. =2? The ringless techni<ue was clinically acceptable and can be used for
the fabrication of fi@ed prosthodontic restorations.
U5:+8%$% O !$ %& '2000)
7(
e+aluated the techni<ue of internal adBustment of
castings with use of duplicated stone dies and a disclosing agent to impro+e marginal fit
discrepancy. Marginal fit discrepancies of copings were significantly reduced with an internal
adBustment techni<ue =mean S 6,O? for all e@perimental groups. Tooth preparations with greater
con+ergence and internally relie+ed castings recorded a better marginal fit. The casting internal
adBustment techni<ue with use of duplicated stone dies and a disclosing agent substantially
reduced marginal fit discrepancy.
A"%9 MF '2002)
*0
characteriAed the elemental compositional stability of as)
recei+ed and recast type ''' gold alloy. The effect of combining these alloys on the marginal
accuracy of complete cast crowns also was e+aluated. !lemental composition was significantly
different among the casting groups =PR.--0?. The mean weight percentage +alues were 9,.2O to
96.9O Au, 2.6O to 9.-O Pd, 0-.9O to 00.0O Ag, 9.:O to :.2O &u, and 0.-O to 0.2O Vn.
Statistically but not clinically significant differences also were found for marginal accuracy. The
marginal discrepancy was less than ,6 >m for all casting conditions, with the lowest +alue
recorded for "roup A =9 >m?, the highest for "roup & =0, >m?, and an intermediate +alue for
"roup / =. >m? specimens. Recasting type ''' gold alloys may ad+ersely affect the marginal
accuracy of complete cast crowns.
I$o M !$ %& '2002)
*1
in+estigated the relationship between wa@ characteristics and the
casting accuracy of a three)<uarter crown. Dental casting accuracy is influenced by the setting
e@pansion of in+estment materials. Although setting e@pansion can help compensate for casting
shrinkage, it cannot be fully realiAed under a confined wa@ pattern. !@actly how soft a wa@
pattern should be to ensure optimum setting e@pansion has not been determined. 3ithin the
limitations of this study, casting shrinkage was affected by the type of wa@ used and was
sensiti+e to the site at which dimensional measurements were performed. The higher the
softening temperature, the larger the casting shrinkage. At gingi+al measurement sites, less
casting shrinkage was found when 0--O special li<uid in+estment was used with all wa@es
e@cept P7:. At facial measurement sites, only S2, e@hibited a significant difference between
0--O and 96O special li<uid in+estments.
B!;;o OL !$ %& '200*)
*2
e+aluated the surface roughness of , base metal alloys,
submitted to different casting techni<ues, to determine the influence of surface roughness on loss
of mass after polishing compared to commercially pure titanium castings. 3ithin the limitations
of this study, the following conclusions were drawnC =0? (acuum casting pro+ided significantly
smoother alloy specimens compared to flame casting. =,? (acuum casting of base metal alloys
pro+ided specimens with a surface smoothness that was not significantly different from those of
commercially pure titanium. =7? There were no significant differences in loss of mass after
polishing for all tested specimens.
G%55+o G !$ %& '200*)
*7
e+aluated the marginal fit of e@perimental and custom)made
fi@ed prosthetic restorations through a new 78-)degree e@ternal e@amination. The minimum
number of gap measurements re<uired to produce rele+ant results for gap analysis was also
in+estigated. The marginal fit of si@ e@perimental and eight custom)made crowns was obser+ed
microscopically by means of a mechanical de+ice, and software was employed to measure the
gap. Two crowns, chosen from among the 02 pre+iously e+aluated, were reanalyAed to determine
the minimum number of gap measurements re<uired to produce significant results for gap
analysis. Differences in fit between e@perimental specimens and custom)made ones showed that
e@perimental results might not always be obtained in clinical practice. 3ithin the limitations of
the protocol of this study, the minimum number of measurements re<uired to ensure rele+ant
results for gap analysis was 0: for e@perimental and .- for custom)made crowns.
M+&% FM !$ %& '200*)
**
e+aluated the relationship between the application of die)
spacer prior to wa@ pattern fabrication and metal remo+al from the inner surface of the casting on
marginal and internal discrepancies of complete cast crowns. $ne hundred and twenty complete
crowns were cast with palladium)sil+er alloy melted by gas)o@ygen torch or electrical resistance
and cast with a centrifuge casting machine. After casting, the crowns were seated on each type of
different marginal configuration dies =.-)degree shoulder, ,-)degree be+eled shoulder, and 26)
degree chamfered shoulder? with a static load of .- % during 0 min. !+aluation of the marginal
fit of the specimens was made using a digital micrometer. The crowns were embedded in acrylic
resin and longitudinally sectioned to +erify the internal discrepancy that occurred in lateral and
occlusal interfaces with a digital micrometer. The data were submitted to A%$(A and TukeyDs
test with a significance le+el of 6O. The best marginal and inner fits were obtained with the gas)
o@ygen torch source. The 26)degree chamfered shoulder showed the best marginal and inner fit,
and better internal relief was obtained in the crowns abraded with 6- >m Al
,
$
7
particles.
A=:"%?%. V- N%69% S !$ %& '2000)
*0
in+estigated the effect of ring liner and casting
ring temperature on the dimensional changes in morphologic cast posts. Prosthodontic treatment
of an endodontically treated tooth poses a challenge to the practitioner. !ndodontic therapy has
pro+ided a solution to retain mutilated teeth. &oronoradicular reconstruction in the form of cast
post and core is used as a method to pro+ide retention and resistance form to the restoration. To
pre+ent fracture and support crown and bridge, reinforcement in the form of intraradicular
de+ices is being used. A cast post is one such method. A cast post and core should fit passi+ely
in the canal. !+en a minimally o+ersiAed post can lead to transfer of stresses to the canal walls
and increase the risk of root fracture. Therefore it is necessary to ensure that there is passi+e fit
of the post and core. Shrinkage of the mould ca+ity is desired during the casting process to allow
a passi+e fit. The effect of lined and unlined rings in the dimensional beha+ior of the in+estment
during setting and subse<uent heating has been in+estigated and it is shown that casting made of
unlined rings are undersiAed.
Bo!2?&!. AF !$ %& '2000)
*
study describes the correlation between obBecti+e
marginal fit and its subBecti+e e+aluation by dentists and dental technicians. All crowns showed
marginal gaps as well as marginal o+ere@tensions. All marginal gaps and o+ere@tensions were in
a clinically acceptable range. $bBecti+e measurement of marginal gaps and o+ere@tended
margins correlated significantly with their subBecti+e e+aluation by dentists and technicians. The
findings regarding the marginal gap and the o+ere@tended margin correlated significantly with
the subBecti+e e+aluation of the clinical acceptability of dentists and technicians. !+aluations of
dentists and technicians showed a significant correlation. The marginal gap had no significant
influence on the decision among dentists and technicians regarding the marginal fit and the
percei+ed clinical acceptability of the tested crowns. $+ere@tended margins had significant
effects on the decision of dentists and technicians regarding marginal fit and clinical
acceptability of the crowns.
B.o5o MR !$ %& '2000)
1
studied to e@amine margin acceptability using an
e@plorer +ersus the actual marginal gap widths at four locations on uncemented crowns on three
e@tracted teeth using both predoctoral students and prosthodontists as e+aluators. 1pon casting,
marginal gaps ranged from 2->m to 806>m. The data pro+ided e+idence that those surfaces
associated with greater marginal gaps tended to ha+e a greater proportion of ratings of Fclinically
unacceptable.DD The proportion of prosthodontists and predoctoral students rating a margin
Fclinically unacceptableDD were highly correlated.
S+6: GP- D%$$% < '2000)
7
e+aluated the marginal gap of complete crowns made
by using wet and dry ceramic ring liners using a scanning electron microscope. Two groups of
thirty castings each were prepared with dry and wet ceramic ring liners respecti+ely and assessed
for marginal fit. Results showed that crowns made by using dry ceramic ring liners had
significantly less marginal gap as compared to the crowns made by using wet ceramic ring liners.
Y%6 CC !$ %& '2007)
*3
e+aluated the characteristics of commercial <uick)heating
phosphate)bonded in+estments. Two different heating methods * the Wuick eating Method
=WM? and &on+entional eating Method =&M? * were used with the in+estments. The
dimensional accuracy and surface roughness of the nickel)chromium alloy castings obtained
from the in+estments were also e@amined. The setting e@pansion =0.0O to ,.,O? was obtained
after a 7-)minute setting timeL the fired strength of both in+estments was greater with WM
=,0., to ,9.9 MPa? than with &M =07.: to 09.. MPa?L the thermal e@pansion of the in+estments
was higher with WM =0.2O T$ 0.9O? than with &M =0.,O to 0.2O?. 'n addition, the surface
roughness of the %i)&r castings obtained from the in+estment was not significantly dependent on
the heating method and the dimensional accuracy of the castings using the in+estments, are
acceptable.
B!9+ A !$ %& '200/)
/
e+aluated the surface roughness and irregularities of gold
palladium alloy castings obtained using different in+estment techni<ues. 3ithin the limitations
of this study, the following conclusions were drawnC =0? The surface roughness +alues of
castings obtained by 2 in+estment techni<ues tested using carbon)free phosphate)bonded
in+estment material were not significantly different. =,? Specimens allowed to set under
atmospheric pressure are more likely to present surface irregularities than specimens set under
positi+e pressure. As a result, adBustment and finishing of the crown can be easier for both the
technician and the clinician, while the fit of the restorations can be impro+ed as well.

Materials )
Metho#s
This study was conducted to measure the +ertical marginal discrepancy and
surface roughness of base metal alloy cast copings made by 'nlay 3a@ and Pattern Resin with
two different methods of casting techni<ues =con+entional casting techni<ue with three stage wa@
elimination and accelerated casting techni<ue?.
The following materials were used for the studyC
0. 'nlay wa@ ="& &orporation, T$E;$, NAPA%? =4ig)6/?.
,. Pattern Resin =Acrylic resin for patterns, "& corporation,T$E;$, NAPA%? =4ig)6A?.
7. Die lubricant =D'! 51/! 3AH S!P, Dentecon, 5osAngeles, 1SA?.
2. Sprue wa@, ,.6mm diameter =;!T' D!%TA5, D1R$%, "!RMA%;?.
6. Ring liner =4le@+est liner, '+oclar (i+adent,"!RMA%;?.
8. Surfactant spray =Aurofilm, /ego, "!RMA%;?.
9. Phosphate bonded in+estment powder =P&T 4le@+est i+oclar +i+adent technical, 'taly?
=4ig)8?.
:. P/' li<uid =P&T 4le@+est li<uid, '+oclar +i+adent technical,'taly? =4ig)8?.
.. Distilled water.
0-. /ase metal %ikel &hromium Alloy =&/:-, D!%TSP5; SA%E'%, NAPA%? =4ig)9?.
00. Aluminium o@ide powder for sand blasting =00- micron? =Delta, '%D'A?.
0,. Separating discs =-.,6 to -.9 mm thickness? =Dentorium, %ew ;ork, 1SA?.
The following e<uipments were used for the studyC
0. Stainless steel master die and stainless steel former assembly =custom)made?
=4ig)0 # ,?.
,. &rucible former =3hip mi@, 1SA?.
7. Alloy casing rings of 2 cm diameter and 6 cm length =3hip mi@, 1SA?.
2. (acuum power mi@er =Tornado product?.
6. Muffle furnace =Technico, Technico laboratory products P(T.5TD, &hennai, '%D'A?.
8. 'nduction casting machine =5&)cast8-, /elgium?.
9. Sand blaster ='deal blaster, Delta, Delta labs, '%D'A?.
:. igh speed alloy grinder =RA; 4$ST!R D!%TA5 !<uipment, &A?.
.. Reichert Poly+ar , met photo microscope =Reichert A1STR'A? =4ig):?.
0-. Stainless steel coping holder for making the cast coping parallel to the ground for
measuring surface roughness =custom)made? =4ig * ,6?.
00. Taly Surf computer controlled surface roughness analyAer =Eosaka lab.? =4ig).?.
Description of custom made stainless steel master die and stainless steel former assemblyC)
The stainless steel master die and stainless steel former =4ig)0 # ,?employed in this
study was custom made, based on the model employed by Eonstantoulakis et al, Schilling et
al for their studies. This assembly essentially is of , parts namely, the stainless steel master
die and the stainless steel former which fits o+er the die. The base has a height of 7-mm and
a diameter of ,-mm.The base is sectioned along its circumference which di+ides it into an
upper one third part and a lower two third part. The upper one third can be mo+ed up and
down from the lower two third of the base. This aids in easy remo+al of wa@ pattern. The
stainless steel master die simulated a crown preparation with a 0-)degree total a@ial wall
taper. The height of the die and its occlusal diameter is 8mm. The occlusal surface had
occlusal cross hairs =or groo+es? to aid in repositioning of the pattern and casting. 4our
markings present on the base of the die, separated by .-)degree, each ser+e as standard
reference points for measurement of the +ertical marginal discrepancy of all the cast copings.
A custom)made stainless steel former was fabricated, such that it can be accurately
positioned o+er the stainless steel master die. The internal surface of the stainless steel former
assembly was larger than the die in all dimensions by -.6mm uniformly. This was done to
maintain a space of -.6mm throughout between the master die and former. This space helped to
obtain the wa@ patterns with a uniform thickness of -.6mm and a .-)degree shoulder margin.
METHODOLOGY
The following methodology was adopted for the studyC
a? 'nlay 3a@ and Pattern Resin fabrication with attachment of sprue and remo+al of
pattern from master die.
b? 'n+esting the 'nlay 3a@ and Pattern Resin separately.
c? 'nlay 3a@ and Pattern Resin burn out procedure with two different techni<ues.
d? &asting procedure.
e? De+esting, sprue cutting and finishing the cast coping.
f? !+aluation of +ertical marginal discrepancy.
g? !+aluation of surface roughness.
This study was conducted to e+aluate the +ertical marginal discrepancy and surface
roughness of 2- cast copings obtained by 2 techni<ues =")', ")'', ")''' and ")'(? as gi+en
belowC
")'C &on+entional casting techni<ue of 'nlay 3a@ copings with 7 stage burnout
procedure =0- samples?.
")''C Accelerated casting techni<ue of 'nlay 3a@ copings with single stage burnout procedure
=0- samples?.
")'''C &on+entional casting techni<ue of Pattern Resin copings with 7 stage burnout procedure
=0- samples?.
")'(C Accelerated casting techni<ue of Pattern Resin copings with single stage burnout
procedure =0- samples?.
a? '%5A; 3AH # R!S'% PATT!R% 4A/R'&AT'$% 3'T ATTA&M!%T $4 SPR1!
A%D R!M$(A5 $4 PATT!R% 4R$M MAST!R D'!C
The custom made stainless steel master die and former assembly as described pre+iously was
used to fabricate standardiAed wa@ and resin pattern. A fine coating of die lubricant =Die 5ube
3a@ sep, Dentecon, 5os Angeles, 1SA? was applied on to the die and the fitting surface of the
stainless steel former using small paint brush for easy remo+al of 'nlay 3a@ and Pattern Resin
from the die and pre+ents the pattern from adhering to the stainless steel former. The stainless
steel former was filled with molten 'nlay 3a@ ="& &orporation, T$E;$, NAPA%? and pressed
on the stainless steel die. The die former assembly was held together for 0 minute with finger
pressure. The die separated from the former and the 3a@ pattern obtained. The e@cess 'nlay 3a@
was trimmed using a PET no.2 car+erM/P blade. 4or easy remo+al of the 3a@ pattern and to
minimiAe distortion, the 'nlay 3a@ pattern was sprued with preformed wa@ sprue =;!T'
D!%TA5, D1R$%, "!RMA%;? of ,.6 mm diameter and ,.6cm length and was attached to the
'nlay 3a@ and Pattern Resin with a reser+oir 7mm from the end of the pattern. $ne end of the
sprue was attached to the pattern at an angle of 26
-
. The 'nlay 3a@ and Pattern Resin was
remo+ed from the die with a gentle pressure and the other end of the sprue was attached to the
crucible former. The 'nlay 3a@ and Pattern Resin was cleaned to obtain clean pattern with
surfactant spray =Aurofilm, /ego, "!RMA%;? to reduce surface tension of all 'nlay 3a@ and
Pattern Resin there by impro+ing wettability with the in+estment. Then pattern was checked with
wa@ caliper to +erify the e+en distribution of -.6mm thickness. A total of ,- 'nlay 3a@ patterns
were fabricated. Similarly ,- Pattern Resin copings were made. They were di+ided into 2
groups, namely ")', ")'', ")''' and ")'( and ten specimens were prepared for each group of the
study.
b? '%(!ST'%" T! '%5A; 3AH # PATT!R% R!S'% S!PARAT!5;C
After spruing each pattern, they were in+ested immediately to minimiAe distortion. &asting
rings were lined with one non o+erlapping layer of wet ceramic ring liner =4le@+est liner, '+oclar
+i+adent, "!RMA%;? by lea+ing 7mm of space below and top. 'nlay 3a@ and Pattern Resin
were in+ested indi+idually with carbon free, phosphate bonded in+estment material =P&T
4le@+est, '+oclar +i+adent technical, 'taly?. The li<uid is prepared by mi@ing the P&T 4le@+est
li<uid with distilled water at a ratio of :-C,- respecti+ely to achie+e optimum e@pansionL
therefore :-- ml of 4le@+est P&T li<uid ='+oclar, +i+adent technical, 'TA5;? was mi@ed
with,-- ml of distilled water to obtain the abo+e mentioned ratio. 3eight of 8- gm of phosphate
bonded in+estment =P&T 4le@+est, '+oclar +i+adent technical, 'taly? was mi@ed with 07ml of
premi@ed li<uid. 'nitially the powder and li<uid mi@ed normally with spatula to wet the powder
particles thoroughly and then mechanical mi@ing was done under +acuum using +acuum mi@er
=Tornado products? for .- seconds. $nce the in+estment was mi@ed the pattern was painted with
a thin layer of in+estment using small paint brush to a+oid air bubble entrapment. The casting
ring =whip mi@, 1SA? was positioned on the crucible former, and the remainder of the
in+estment was poured slowly in to the ring under +ibrations. !@cessi+e +ibration is a+oided to
pre+ent formation of the bubbles and separation of the pattern from the sprue. The in+estment
pattern was allowed to bench set for 7- minutes. All the 2- patterns in four groups are in+ested
in the same procedure.
c? '%5A; 3AH # PATT!R% R!S'% /1R% $1T PR$&!D1R! 3'T T3$ D'44!R!%T
T!&%'W1!SC
The 'nlay 3a@ and Pattern Resin burnout procedure is different for each of the four test
groups =")', ")'', ")''' and ")'(? as described belowC
0? ")'C &on+entional casting techni<ue of 'nlay 3a@ copings with 7 stage burnout procedure
=0- samples?
After a 7- minute bench set time, the set in+estment mold ring was placed in burnout
furnace =Technico, Technico laboratory products P(T 5TD, &hennai, '%D'A?. The wa@ burnout
was done using a programmed preheating schedule, i.e. the ring was kept in the furnace at room
temperature and was heated till

,9-
-
c rise of temp at a rate of :
-
c M min and was held at this
temperature for 7- min. Then ring was heated from ,9-
-
c to 68-
-
c rise of temp at a rate of :
-
c M
min and was held at this temperature for 7- min. Terminal burnout was carried out from 68-
-
c
to :6-
-
c rise of temp at a rate of :
-
c M min and was held at this temperature for 7- min. The
in+estment mold was placed initially into the furnace such that it allows for the escape of molten
wa@ and +apours. The in+estment mold was later a+erted near the end of the burnout cycle with
the sprue hole facing upward to enable escape of the entrapped gases and allow o@ygen to
contact to ensure complete burnout of the wa@ pattern and mold e@pansion.
,? ")''C Accelerated casting techni<ue of 'nlay 3a@ copings with single stage burnout
procedure =0- samples?
After a 7- minute bench set time, the set in+estment mold ring was placed directly in a
preheated burnout furnace =Technico, Technico laboratory products P(T 5TD, &hennai, '%D'A?
at :6-
-
c, and held for 7- min to ensure complete burnout of the wa@ pattern. The in+estment
mold was placed into the furnace such that it allows for the escape of molten wa@ and +apours.
The in+estment mold was later a+erted near the end of the burnout cycle with the sprue hole
facing upward to enable escape of the entrapped gases # allow o@ygen to contact to ensure
complete burnout of the wa@ pattern # mold e@pansion.
7? ")'''C &on+entional casting techni<ue of Pattern Resin copings with 7 stage burnout
procedure =0- samples?
After a 7- minute bench set time, the set in+estment mold ring was placed in burnout
furnace =Technico, Technico laboratory products P(T 5TD, &hennai, '%D'A?. The resin
burnout was done using a programmed preheating schedule, i.e. the ring was kept in the furnace
at room temperature and was heated till

,9-
-
c rise of temp at a rate of :
-
c M min and was held at
this temperature for 2- min. Then ring was heated from ,9-
-
c to 68-
-
c rise of temp at a rate of
:
-
c M min and was held at this temperature for 2- min. Terminal burnout was conducted from
68-
-
c to :6-
-
c rise of temp at a rate of :
-
c M min and was held at this temperature for 2- min.
The in+estment mold was placed initially into the furnace such that it allows for the escape of
molten Pattern Resin and +apours. The in+estment mold was later a+erted near the end of the
burnout cycle with the sprue hole facing upward to enable escape of the entrapped gases and
allow o@ygen to contact to ensure complete burnout of the Pattern Resin and mold e@pansion.
2? ")'(C Accelerated casting techni<ue of Pattern Resin copings with single stage burnout
procedure =0- samples?
After a 7- minute bench set time, the set in+estment mold ring was placed directly in a
preheated burnout furnace =Technico, Technico laboratory products P(T 5TD, &hennai, '%D'A?
at :6-
-
c, and held for 2- min to ensure complete burnout of the Pattern Resin. The in+estment
mold was placed into the furnace such that it allows for the escape of molten Pattern Resin and
+apours. The in+estment mold was later a+erted near the end of the burnout cycle with the sprue
hole facing upward to enable escape of the entrapped gases # allow o@ygen to contact to ensure
complete burnout of the Pattern Resin # mold e@pansion.
d? &AST'%" PR$&!D1R!C
The casting procedure was performed <uickly to pre+ent heat loss from the ring resulting in
the thermal contraction of the mold. The preheated casting crucible and the in+estment mold
were taken out of the furnace and were placed in the casting machine. The casting was done in
an induction casting machine =5&)&ast 8-?. The %ickel)&hromium alloy =&/ :-, non precious
alloy, D!%TSP5;? was heated sufficiently till the alloy ingot turned to molten state and the
le+er was released and centrifugal force ensures the completion of the casting procedure.
'n+estment was allowed to cool down to room temperature. The casting procedure followed was
same for all the test samples. A total of 2- castings were made to obtain cast copings for the
e+aluation in this study. Among the 2- castings 0- were obtained for ")' techni<ue, 0- for ")''
techni<ue, 0- for ")''' techni<ue and 0- for ")'( techni<ue.
e? D!(!ST'%", SPR1! &1TT'%" A%D 4'%'S'%" T! &AST'%"C
4ollowing casting, the hot casting ring was bench cooled to room temperature, and
de+esting was carried out carefully by tapping the button of the casting with mallet. Adherent
in+estment was remo+ed from the casting initially with hand instrument and then by sandblasting
with 00- micron alumina at :- psi pressure. The sprue was remo+ed at the Bunction of the coping
with an ultra thin abrasi+e disc =Dentorium, %ew ;ork, 1SA? and the copings were subBected to
ultrasonic cleaning # checked +isually. The internal surface was inspected # relie+ed of all
nodules with a round carbide bur. This procedure was followed for each of the ten samples of the
four test groups.
f? !(A51AT'$% $4 (!RT'&A5 MAR"'%A5 D'S&R!PA%&;C
!ach casting was seated on the stainless steel die with finger pressure until
resistance was met. Microscopic measurements were recorded at :- H magnification
perpendicular to the a@ial wall with a photomicroscope =Reichert Poly+ar , met
photomicroscope, Reichert, A1STR'A? at the department of %uclear Physics, Madras
1ni+ersity, &hennai, '%D'A. Measurements were recorded from coping margin to the stainless
steel die margin for +ertical marginal discrepancy. Marginal discrepancies were measured to the
nearest micron on each casting at the 2 predetermined sites on the base of the stainless steel die
separated by .-
-
each. The same procedure was followed to record the +ertical marginal
discrepancy for each of the ten test samples belonging to the four test groups. The measurements
thus obtained were tabulated and statistically analyAed.
g? !(A51AT'$% $4 S1R4A&! R$1"%!SSC
Description of custom) made stainless steel coping holder for measuring surface roughnessC
4or measuring surface roughness the cast metal coping should be e@actly perpendicular
to the diamond indentor. The stainless steel coping holder employed for measuring surface
roughness was custom)made, with dimensions of 6cm in length, 6cm in breadth and 0.6cm in
height. The coping holder has a depression horiAontally in the center to accommodate the coping
precisely in to it. The dimensions of the depression were 8.6mm in length, 7.6mm in depth at the
base of the coping, 7.,6mm in depth at occlusal surface of the coping with a taper of 0-
-
from
base to top of the coping. $nly half of the coping will be inside the depression, when it is placed
horiAontally in the custom)made stainless steel coping holder.
!ach metal coping was placed horiAontally on the coping holder for making the coping
perpendicular to the diamond indentor. The surface roughness was measured by passing the
diamond indentor o+er the coping surface for a distance of 0.8mm.The readings were obtained
graphically as crest and troughs with surface roughness analyAer =Taly Surf &omputer "uided
Surface Roughness AnalyAer, Eosaka 5ab? at the Manufacturing !ngineering Department, Anna
1ni+ersity, &hennai, '%D'A. Surface roughness was measured to the nearest micron at 7
surfaces on the coping. The same procedure was followed to record the surface roughness for
each of the ten test samples belonging to the four test groups. The measurements thus obtained
were tabulated and statistically analyAed.
4ig)0 A@ial +iew of custom made stainless steel former
assembly =A? and stainless steel master die =/?
B A
8 MM
.! MM
4ig), $cclusal (iew of &ustom made stainless steel former
assembly =A? and stainless steel master die =/?
B
A
4ig )7a. 5ine Diagram of custom) made stainless steel master die.
7b. 5ine diagram of custom)made stainless former
20 mm
22 mm
2 mm
mm
!
0

.! mm
mm
3a
20 mm
20 mm
.! mm
" mm
3b
b




4ig * 2 5ine diagram of custom)made stainless steel master die # stainless steel former in
place. &olored space indicates the space for wa@ pattern.
a . &ustom * made stainless steel die. b. &ustom) made stainless steel former.
a
4ig * 6A Pattern Resin, 6/ 'nlay wa@
A
B





4ig * 8 'n+estment powder # special
5i<uid
4ig * 9 %ickel * &hromium alloy
4ig * : Photo Microscope
4ig * . Surface Roughness analyAer




4ig * 0- Preparation of 'nlay 3a@
Pattern
4ig * 00 Preparation of Pattern Resin
4ig * 0, 3a@ coping showing -.6mm
thickness
4ig * 07 Pattern Resin coping showing
-.6mm thickness
4ig * 02 3a@ Pattern attached to crucible
former
4ig * 06 Ring 5iner Placed 7mm
short of Ring Margin
4ig * 09 Di+ested casting 4ig * 08 3a@ pattern in position in
the casting ring
4ig * 0: &ast coping seated on the die
4ig * 0. Metal &oping showing -.6mm thickness
4ig * ,- Marginal gap of 72.-, at :-@ magnification by using photo
microscope of a cast coping obtained by con+entional casting techni<ue
employing three stage wa@ elimination. a) Margin of custom made
stainless steel die, b)Marginal gap, c) Margin of cast coping
4ig * ,0 Marginal gap of 22.7. at :-@ magnification by using
photo microscope of a cast coping obtained by Accelerated casting
techni<ue employing single stage wa@ elimination

a c
b
a c
b
4ig * ,, Marginal gap of 79.-8 at :-@ magnification by using photo
microscope of a cast coping obtained by con+entional casting techni<ue
employing three stage Resin elimination

4ig * ,7 Marginal gap of 28.:8 at :-@ magnification by using photo
microscope of a cast coping obtained by Accelerated casting techni<ue
employing single stage Resin elimination

a
c
b
a c
b


.!m
m mm
! cm
#.! cm
4ig * ,6 &ustom made stainless steel
coping holder with coping
4ig * ,2 line diagram of custom made stainless steel coping
holder
4ig * ,8 &ustom made stainless steel
coping holder with coping on surface
roughness AnalyAer

&utoff -.:mm
!.length ,.790mm
S.length 0.0:6mm
Ra 2..>m
Ry ,..8>m
RA ,0.7>m

&utoff -.:mm
!.length 0.-02mm
S.length 0.-02mm
Ra 2.2>m
Ry ,6.6>m
RA ,0.,>m
4ig * ,9 surface roughness graph obtained by con+entional casting techni<ue
with three stage wa@ elimination
Ra ) Roughness A+erage
Ry * Ma@imum height of the profile
RA * A+erage Ma@imum height of the Profile
4ig * ,: surface roughness graph obtained by Accelerated casting techni<ue with
single stage wa@ elimination
S.5ength * Sampling 5ength !. 5ength * !+aluation 5ength
&utoff -.:mm
!.length 0.072mm
S.length 0.072mm
Ra 0-.9>m
Ry 8..7>m
RA 78.8>mX
&utoff -.:mm
!.length 0.8--mm
S.length -.:--mm
Ra 9.0>m
Ry 2:.6>m
RA 7,.2>mX
4ig * ,. surface roughness graph obtained by con+entional casting techni<ue with
three stage Resin elimination
4ig * 7- surface roughness graph obtained by Accelerated casting techni<ue with
single stage Resin elimination

!esults

Table 0 shows the basic data of the results and mean obtained in ")' =&on+entional casting
techni<ue of 'nlay 3a@ copings with 7 stage burnout procedure? to e+aluate the +ertical marginal
discrepancy in microns =Y?.
T)*+,
S.N-. P-./0 "1# P-./0 2"1# P-./0 $"1# P-./0 %"1# M,)/"1#
0 ,:.02 79.26 ,:.88 ,..-, 7-.:,
, 76.08 ,...8 7,.20 2-.60 72.60
7 78.,8 79.62 70.-6 7-.,. 77.9:
2 7..-8 20.6, 70.70 77.28 78.72
6 ,..0- 7,.:9 78.9, ,..82 7,.-:
8 28.06 7,.89 70.-0 ,:.08 72.6-
9 72.,8 7:.02 70.76 26.0: 79.,7
: 76.6. 2,.77 ,..02 7-.,7 72.7,
. 7-.-. 70.00 ,..:0 7:.96 7,.22
0- 78.8- 77.62 7-.82 78.-6 72.,0
Table , shows the basic data of the results and mean obtained in ")'' =Accelerated casting
techni<ue of 'nlay 3a@ copings with single stage burnout procedure? to e+aluate the +ertical
marginal discrepancy in microns =Y?.
T)*+, 2
S.N-. P-./0 "1# P-./0 2"1# P-./0 $"1# P-./0 %"1# M,)/"1#
0 26.99 26.89 7..79 26.-: 27..9
, 27.26 7:.-8 2-.:: 22.09 20.82
7 2-.6. 76.:8 27.,, 2,.26 2-.67
2 2,.69 28.90 26.8, 26.:0 26.0:
6 28.99 20.-: 2..,: 28.:9 28.--
8 28.-: 28.00 26.,6 28.02 26..-
9 22.6: 27.,. 26.-0 29.:9 26.0.
: 26.92 2,.-6 20.6, 26..9 27.:,
. 28.,, 2:.28 27.-. 29.,6 28.,8
0- 29.7, 2,.9. 22..0 28.98 26.22
Table 7 shows the basic data of the results and mean obtained in ")''' =&on+entional casting
techni<ue of Pattern Resin copings with 7 stage burnout procedure? to e+aluate the +ertical
marginal discrepancy in microns =Y?.
T)*+, $
S.N-. P-./0 "1# P-./0 2"1# P-./0 $"1# P-./0 %"1# M,)/"1#
0 7,.98 79.27 76.8: 2-.6, 78.8-
, 20.6, 76.9: 70.:8 79.2. 78.88
7 7:.,2 78.9, 2,.-6 7..80 7..08
2 27.9, 72.86 7,.27 7,.26 76.:0
6 78.,. 7-.,2 7..89 20.06 78.:2
8 2,.,2 2-.06 7:.-. 76.9: 7..-9
9 20.,, 79.8, 7-.06 72.8, 76..-
: 7..:, 22.6. 7,.0: 76.78 79...
. 77.2, 78.9: ,..,0 72.8, 77.60
0- 76.8. 7:.69 7..:8 2,.-. 7..-6
Table 2 shows the basic data of the results and mean obtained in ")'( =Accelerated casting
techni<ue of Pattern Resin copings with single stage burnout procedure? to e+aluate the +ertical
marginal discrepancy in microns =Y?.
T)*+, %
S.N-. P-./0 "1# P-./0 2"1# P-./0 $"1# P-./0 %"1# M,)/"1#
0 60.,6 2..8, 26.:9 28.96 2:.79
, 2..8, 2-.90 7..:6 27.8, 27.26
7 2,.89 7:.96 2,.,7 7..0, 2-.8.
2 22.07 6-.,, 28.06 2..9, 29.68
6 28.:8 27.0, 2..79 60.08 29.87
8 29.0, 28.:6 60.7, 6-.09 2:.:8
9 26.6, 27.90 28.-, 29.8. 26.92
: 28.82 7..,, 60.,. 2..68 28.8:
. 66.8, 6-.76 29.., 29.., 6-.86
0- 26.00 29..7 67.0. 2..98 2..--
"raph 0 shows the basic data of the results and mean obtained in ")' =&on+entional casting
techni<ue of 'nlay 3a@ copings with 7 stage burnout procedure? to e+aluate the +ertical marginal
discrepancy in microns =Y?.
Gr)23
"raph , shows the basic data of the results and mean obtained in ")'' =Accelerated casting
techni<ue of 'nlay 3a@ copings with single stage burnout procedure? to e+aluate the +ertical
marginal discrepancy in microns =Y?.
Gr)23 2
"raph 7 shows the basic data of the results and mean obtained in ")''' =&on+entional casting
techni<ue of Pattern Resin copings with 7 stage burnout procedure? to e+aluate the +ertical
marginal discrepancy in microns =Y?.
Gr)23 $
"raph 2 shows the basic data of the results and mean obtained in ")'( =Accelerated casting
techni<ue of Pattern Resin copings with single stage burnout procedure? to e+aluate the +ertical
marginal discrepancy in microns =Y?.
Gr)23 %


Table 6 shows the mean +ertical marginal discrepancy obtained from basic mean +alues of four
techni<ues =")', ")'', ")''' and ")'(? calculated in microns =Y?.
T)*+, &
G-I"1# G-II"1# G-III"1# G-IV"1#
M,)/ "4# $%.02 %%.$9 $7.0' %'.('
"raph 6 shows the comparison of the mean +ertical marginal discrepancy obtained from basic
mean +alues of four techni<ues.
Gr)23 &

The obtained results were statistically analysed, mean and standard de+iations were
estimated for each study group. The data were analyAed by use of t)test. 'n the present study,
pR-.--0 was considered as the le+el of significance.
Table 8 shows the test of significance for the mean obtained from four techni<ues =")', ")'', ")
''' and ")'(?. t)test was used to calculate the P +alue.
T)*+, '
T,53/.67, M,)/"4# S.D. 2-8)+7,
G-I $%.02 .9
90.00
::
G-II %%.$9 .9$
G-III $7.0' .(0
G-IV %'.(' 2.9$
N-0,: - XX denotes significant at 0O le+el.
X denotes significant at 6O le+el.
I/;,r,/5,:
The table 8 shows the comparison of the mean +alue of the +ertical marginal discrepancy
obtained for each of the four techni<ues. Since the p)+alue is less than -.--0, there is highly
significant difference between the four techni<ues with regard to +ertical marginal discrepancy.
The mean +ertical marginal discrepancy +alues obtained from the two con+entional casting
techni<ues ")' =72.-,>? and ")''' =79.-8>? has minimal statistical difference. The mean +ertical
discrepancy +alues obtained from the two accelerated casting techni<ues ")'' =22.7.>? and ")'(
=28.:8>? has minimal statistical difference. owe+er higher +alues of +ertical marginal
discrepancy were found with accelerated casting techni<ues ")'' =22.7.>? and ")'( =28.:8>?
when compared to the con+entional casting techni<ues ")' =72.-,>? and ")''' =79.-8>? and this
difference was statistically significant.
Table 9 shows the basic data of the results and mean obtained in ")' =&on+entional casting
techni<ue of 'nlay 3a@ copings with 7 stage burnout procedure? to e+aluate the surface
roughness in microns =Y?.

T)*+, 7
S.N-. Ar,) "1# Ar,) 2"1# Ar,) $"1# M,)/"1#
0 2..- 6.2- 6..- 6.2-
, 2.8- 6.6- 8.,- 6.27
7 7.9- 2.0- 2.7- 2.-7
2 2.,- 7..- 2.0- 2.-9
6 7.:- 2.7- 2.,- 2.0-
8 2.2- 7.9- 2.0- 2.-9
9 2.,- 7.:- 2.-- 2.--
: 2.:- 2.0- 2.2- 2.27
. 6.-- 2.,- 2.7- 2.6-
0- 7.9- 2.0- 7.8- 7.:-

Table : shows the basic data of the results and mean obtained in ")'' =Accelerated casting
techni<ue of 'nlay 3a@ copings with single stage burnout procedure? to e+aluate the surface
roughness in microns =Y?.
T)*+, (
S.N-. Ar,) "1# Ar,) 2"1# Ar,) $"1# M,)/"1#
0 2..- 2.2- 6.8- 2..9
, 2.,- 9.7- 2.6- 6.77
7 2.8- 8..- 2.6- 6.77
2 8.7- 6.:- 8.0- 8.-9
6 8.,- 8.-- 6..- 8.-7
8 2.:- 6.6- 6.9- 6.77
9 6.,- 2..- 2.9- 2..7
: 2.9- 6.7- 6.0- 6.-7
. 8.0- 6.9- 6.2- 6.97
0- 6.:- 6.6- 2.:- 6.79
Table . shows the basic data of the results and mean obtained in ")''' =&on+entional casting
techni<ue of Pattern Resin copings with 7 stage burnout procedure? to e+aluate the surface
roughness in microns =Y?.
T)*+, 9
S.N-. Ar,) "1# Ar,) 2"1# Ar,) $"1# M,)/"1#
0 8.2- 0-.9- 8.7- 9.:-
, 0-.,- 9.-- 8.2- 9.:9
7 7.2- 2.-- 6.:- 2.2-
2 :.9- ..,- 9.0- :.77
6 ..7- 9.8- :.0- :.77
8 0-.0- :.9- 8.7- :.79
9 ..9- 8.6- :.,- 9.07
: 2..- :.7- 0-.9- 9..9
. 9.7- 0-.8- ..2- ..0-
0- 8.9- 9.6- :.:- 9.89
Table 0- shows the basic data of the results and mean obtained in ")'( =Accelerated casting
techni<ue of Pattern Resin copings with single stage burnout procedure? to e+aluate the surface
roughness in microns =Y?.
T)*+, 0
S.N-. Ar,) "1# Ar,) 2"1# Ar,) $"1# M,)/"1#
0 7.,- 0,.0- 0,.,- ..09
, 6.0, 0-.6- 9.0- 9.69
7 6.9- 8.,- :.7- 8.97
2 00.8- 6.9- :..- :.97
6 :.6- 0,.8- ..2- 0-.09
8 ..9- 0-..- 00.9- 0-.99
9 0-.:- 00.8- :.9- 0-.79
: 8..- 0-.6- :.8- :.89
. :.9- 00.:- ..8- 0-.-7
0- 0,.6- ..9- :.2- 0-.,-
"raph 8 shows the basic data of the results and mean obtained in ")' =&on+entional casting
techni<ue of 'nlay 3a@ copings with 7 stage burnout procedure? to e+aluate the surface
roughness in microns =Y?.
Gr)23 '

"raph 9 shows the basic data of the results and mean obtained in ")'' =Accelerated casting
techni<ue of 'nlay 3a@ copings with single stage burnout procedure? to e+aluate the surface
roughness in microns =Y?.
Gr)23 7

"raph : shows the basic data of the results and mean obtained in ")''' =&on+entional casting
techni<ue of Pattern Resin copings with 7 stage burnout procedure? to e+aluate the surface
roughness in microns =Y?.
Gr)23 (
"raph . shows the basic data of the results and mean obtained in ")'( =Accelerated casting
techni<ue of Pattern Resin copings with single stage burnout procedure? to e+aluate the surface
roughness in microns =Y?.
Gr)23 9
Table 00 shows the mean surface roughness obtained from basic mean +alues of four techni<ues
=")', ")'', ")''' and ")'(? calculated in microns =Y?.
T)*+,
G-I"1# G-II"1# G-III"1# G-IV"1#
M,)/ "4# %.$( &.% 7.( 9.2%
"raph 0- shows the comparison of mean surface roughness obtained from basic mean +alues of
2 techni<ues.
Gr)23 0
The obtained results were statistically analysed, mean and standard de+iations
were estimated for each study group. The data were analyAed by use of t)test. 'n the present
study, pR-.--0 was considered as the le+el of significance.
Table 0, shows the test of significance for the mean obtained from four techni<ues =")', ")'', ")
''' and ")'(?. t)test was used to calculate the p)+alue.
T)*+, 2
T,53/.67, M,)/"4# S.D. 2-8)+7,
G-I %.$( 0.&(
90.00
::
G-II &.% 0.%
G-III 7.( .2'
G-IV 9.2% .$2
I/;,r,/5,:
The table 0, shows the comparison of the mean +alue of the surface roughness obtained
for each of the four techni<ues. Since the p)+alue is less than -.--0, there is highly significant
difference between the four techni<ues with regard to surface roughness. The mean surface
roughness +alues obtained from castings done with 'nlay 3a@ in ")' =2.7:>? and ")'' =6.20>?
techni<ues has minimal statistical difference. owe+er higher +alues of surface roughness were
found from castings done with Pattern Resin in both ")''' =9.:>? and ")'( =..,2>? techni<ues
and this difference was statistically significant.


Dis-ussion
&asting metals by lost)wa@ process has been recogniAed in industry and in arts for many
years. %o record e@ists when and where this type of casting procedure was first de+eloped.
,8
'n
dentistry lost wa@ process of casting metals became common practice after it was introduced by
Taggart in 0.-9.
.
&astings made by Taggart were generally too small and did not fit the ca+ities
properly.
,, ,8
The fit of a casting can be defined best in terms of FmisfitG measured at +arious points
between the casting surface and the tooth. Measurements between the casting and the tooth can
be made from points along the internal surface of the margin or on the e@ternal surface of the
casting.
2,6
&linically important measurements are the marginal gap, which is the distance from the
internal surface of the casting to the a@ial wall of the preparation at the margin.
2
The accuracy of fit of casting is essential for longe+ity and clinical success of the cast
restoration in the oral ca+ity.
7
5ack of ade<uate fit is potentially detrimental to both the tooth and
the periodontal tissues. &linically, defecti+e margins act as a niche for pla<ue. 'nsufficient
marginal fit can cause secondary caries below the margins of the crown.
2, 6, 00, 7:
Precise marginal
sealing is important in dental restorations to fulfill biologic, physical and cosmetic re<uirements
lest the restoration will fail.
Marginal discrepancies are ine+itable, despite careful attention to wa@ing, in+esting and
casting. 't is one of the tasks of the luting cement to close these discrepancies. owe+er, cement
can be washed out under the margins if gap is too large.
2
/ecause of their solubility, luting
cements in general, ha+e been described as weak link in restoring teeth with cast restorations.
,.
The rate of cement dissolution has been related empirically to the degree of marginal opening,
thus larger the marginal gap and subse<uent e@posure of the dental luting cement to oral fluids,
the more rapid is the rate of cement dissolution.
,.
Thus for the success of cast restoration,
marginal gap must be as minimal as possible.
4rom the time that dental castings were first introduced, at about the turn of the century,
efforts ha+e been made to produce more accurate and better fitting casting with minimal
marginal discrepancy.
,2
The accuracy of fit is affected by the <uality of tooth preparation, the
impression, the working cast, the <uality of the wa@ that is used, and the accuracy of the casting
procedures. The accuracy of casting is subBected to the +olumetric changes occurring due to
shrinkage of wa@ and alloys. This shrinkage can be compensated by normal setting e@pansion,
hygroscopic e@pansion andMor thermal e@pansion of the in+estment.
,, 7
The casting process used in dentistry based on the lost wa@ techni<ue has been recei+ing
continuous in+estigations. The maBority of the efforts deal with the con+entional casting
techni<ue. The con+entional in+esting and casting techni<ues re<uire atleast 0 hour bench set for
the in+estment. The usual burnout temperatures for phosphate)bonded in+estments range from
96-
-
to 0-7-
-
&. The highest temperatures are re<uired for base metal alloys, especially those that
are used for ceramometal restorations. 'nitially one stage wa@ burnout procedure was followed
traditionally to achie+e complete burnout as well as thermal e@pansion. 5ater on manufacturers
added a two or three stage burnout procedures to con+entional techni<ues to achie+e ma@imum
thermal e@pansion by ma@imum con+ersion of the refractory used in the in+estment. The entire
process in+ol+ing phosphate)bonded in+estments takes a long timeL the demand for time sa+ing
is more. 'n+estment manufacturers ha+e attempted to answer this demand and accelerated casting
techni<ues ha+e been reported in an effort to achie+e similar <uality results in significantly less
time. These techni<ues ha+e the ability to shorten the in+esting and casting process, there by
impro+ing producti+ity. This accelerated techni<ue uses a typical method of setting and burnout
of the phosphate)bonded in+estment.
1sually, a bench setting time of 0, to 06 minutes and a mold burnout time of 0, to 06
minutes are employed before the casting process. The first published attempt to accelerate the
lost wa@ techni<ue with the use of phosphate)bonded in+estment for complete crown was made
in 0.:: by MarAouk and Eerby who recogniAed the importance of in+estment temperature. Their
study re+ealed no statistical circumferential difference between in+estment groups introduced in
a 076-
-
& preheated o+en after 06 minute bench set and the con+entional techni<ue.
0,
&ampagni
et al
7-
tested the fit of dowel and cores made of noble alloy by an accelerated casting techni<ue,
and similar studies were subse<uently conducted by /ailey and Sherrard and Schneider.
7,,77
All
these in+estigations concluded that the use of a predetermined bench set time reduced in+estment
weakness and that standardiAed accelerated procedures for all types of in+estments were
inad+isable.
0,
/lackman
00
measured marginal sharpness and diameter changes for crowns cast with type '''
gold alloy by using phosphate)bonded in+estment and rapid burnout techni<ues, and concluded
that rapid mold preparation resulted in loss of marginal fineness. Eonstantoulakis
.
e+aluated the
marginal fit and surface roughness of complete cast crowns made with a con+entional and
accelerated casting techni<ue and reported that crowns fabricated with the accelerated casting
techni<ue were not significantly different from those fabricated with con+entional techni<ue.
Schilling et al
0,
e+aluated marginal gap of crowns made with a phosphate)bonded in+estment and
accelerated techni<ue and reported that the marginal gaps for castings made with an accelerated
techni<ue showed no statistical difference when compared with con+entional casting techni<ue.
The accuracy of base metal alloy castings obtained by different in+esting and burnout procedures
with phosphate)bonded in+estments were not ade<uately studied. Though studies
.,0,
ha+e
reported that marginal discrepancies by accelerated casting techni<ue are within the clinically
acceptable limits, some studies
.,00,0,
ha+e reported that this procedure is techni<ue sensiti+e.
Surface roughness of dental castings is an important aspect of their <uality and can potentially
affect their marginal fit and the time re<uired for finishing and polishing. 't is preferable that the
surface of as)cast crowns be smoother to obtain better marginal fit and curtail finishing or
polishing time. Surface roughness of castings is belie+ed to be affected by se+eral factors such as
type of alloy, mold material, mold temperature, wa@ pattern, and casting machine.
.
/edi et al
reported that specimens set under atmospheric pressure are much more likely to present surface
irregularities than specimens set under positi+e pressure. The use of pressure can help produce
castings with fewer surface irregularities.
:
Thus, the fit of the casting is a critical issue in determining the longe+ity of the restoration
and in+esting and burnout procedures are an important parameter in determining the <uality of
the fit of the casting. The surface roughness of the casting affects the ceramic)metal interface
bond. ence, this study was conducted to in+estigate the differences in the marginal discrepancy
and surface roughness of base metal alloy cast copings employing two different techni<ues with
two different materials to achie+e thermal e@pansion of the in+estment. The introduction of
ceramometal technology re<uired the use of higher melting range alloys to with stand the firing
cycle of porcelain with out noticeable distortion. /ase metal alloys are one of the alloys that are
routinely used for obtaining ceramometal restorations. The alloy used in this study was a nickel)
chromium alloy used for ceramometal restorations. An in+estment that can resist higher
temperatures and higher stress during casting
,
is re<uired. A phosphate)bonded in+estment
fulfills these re<uirements and hence used in this study.
A custom made stainless steel master die was used to fabricate the standardiAed 'nlay 3a@ and
Pattern Resin. The master die was based on the models employed in similar pre+ious studies.
.,0,
This standardiAed stainless steel dies facilitated in standardiAing the dimensions of the test 'nlay
3a@ and Pattern Resin. 4our markings present on the base of the die, separated by .-)degree,
each ser+e as standard reference points for measurement of the +ertical marginal discrepancy of
all the cast copings. Another custom made stainless steel coping holder was used for
measurement of the surface roughness. This coping holder was fabricated for making the coping
perpendicular to the surface roughness analyAer. !ach pattern was immediately in+ested to
minimiAe distortion.
,,7,0,
Different ratios of special li<uid to distilled water ha+e been
recommended to obtain the re<uired mold e@pansion. 'n this study, the ratio of special li<uid to
distilled water of appro@imately :-C,- in +olume was employed. This special li<uid to distilled
water ratio has been shown to offer ade<uate e@pansion for complete crown castings, as
recommended by the manufacturer and hence employed in this study. The li<uid to powder ratio
was as recommended by the manufacturer i.e., 8-g powder)07ml li<uid.
(acuum mi@ing was done and in+esting of all the samples was done as recommended by the
manufacturer. Two different techni<ues with two different materials were used for achie+ing
complete burnoutC con+entional casting techni<ue with three stage 'nlay 3a@ and Pattern Resin
elimination, accelerated casting techni<ue with single stage 'nlay 3a@ and Pattern Resin
elimination.
The con+entional burnout procedures usually recommend burn out temperatures for
phosphate)bonded in+estments in a range of 96-
-
c to 0-7-
-
c. The highest temperatures are
re<uired for base metal alloys, especially those that are used for ceramometal restorations.
8
Some
manufacturers recommend additional holding stages =either ,)stageM7)stage? during burn out for
their in+estments. This could be attributed to ma@imum con+ersion of the refractories used in the
in+estment there by achie+ing ma@imum e@pansion of the in+estment. A three stage burn out
procedure was employed for obtaining the cast copings for the con+entional techni<ue as it was
recommended by the manufacturer =P&T 4le@+est, '+oclar? of the in+estment employed in this
study.
Accelerated techni<ues are time sa+ing and hence offer ad+antage to commercial laboratories.
The pattern is in+ested, casted, and deli+ered in a cost)effecti+e, time)sa+ing manner.
Accelerated casting techni<ue was employed for obtaining the cast copings for the second and
fourth test groups in this study. The manufacturer of the phosphate)bonded in+estment material
=P&T 4le@+est? employed in this study recommends that the in+estment can be used for an
accelerated as well as for the con+entional casting techni<ue with three stage wa@Mresin
elimination. ence, this material was chosen for in+esting the wa@Mresin for all the test groups in
this study. Also using a single in+estment material for all the test groups helps to eliminate any
+ariability in the test results.
The casting procedure was performed by using an induction casting machine. All castings,
one at a time were seated on the stainless steel die with finger pressure till the resistance is
obtained and the +ertical marginal discrepancy was measured on four predetermined areas that
were marked on the metal die using a photomicroscope =Reichert Poly+ar , met photo
microscope, Reichert, A1STR'A? at a magnification of :-H. The results of this study ha+e been
tabulated as a basic data and interpretation of this data was done by statistical analysis.
All castings, one at a time were seated on the stainless steel die and the surface roughness
was measured on three surfaces using a Taly Surf computer controlled surface roughness
analyAer =Eosaka lab.?
The basic data for +ertical marginal discrepancy shows a mean +alue of 72.-, >m
for con+entional casting techni<ue of 'nlay 3a@ copings with three stage burn out procedure =")
'?, 22.7. >m for accelerated casting techni<ue of 'nlay 3a@ copings with single stage burn out
procedure =")''?, 79.-8 >m for con+entional casting techni<ue of Pattern Resin copings with 7
stage burn out procedure =")'''? and 28.:8 >m for accelerated casting techni<ue of Pattern Resin
copings with single stage burn out procedure =")'(?.
The basic data for surface roughness shows a mean +alue of 2.7: >m for con+entional
casting techni<ue of 'nlay 3a@ copings with three stage burn out procedure =")'?, 6.20 >m for
accelerated casting techni<ue of 'nlay 3a@ copings with single stage burn out procedure =")''?,
9.:- >m for con+entional casting techni<ue of Pattern Resin copings with 7 stage burn out
procedure =")'''? and ..,2 >m for accelerated casting techni<ue of Pattern Resin copings with
single stage burn out procedure =")'(?.
The statistical analysis by t)test indicated that the difference in the +ertical marginal
discrepancy and surface roughness measurements for the four techni<ues showed the p)+alue of
R -.--0. This denotes significance at 0O le+el. The mean +ertical marginal discrepancy +alues
obtained with the two con+entional casting techni<ues has minimal statistical difference between
copings made with 'nlay 3a@ and Pattern Resin. owe+er higher +alues of +ertical marginal
discrepancy were found with accelerated casting techni<ue copings made with 'nlay 3a@ and
Pattern Resin when compared with the con+entional casting techni<ue.
The mean surface roughness +alues obtained with the copings made with
'nlay 3a@ has minimal statistical difference in both ")' and ")'' techni<ues. owe+er higher
+alues of surface roughness were found with copings made with Pattern Resin in both ")''' and
")'( techni<ues.
The results indicate that, with in the limitations of the study, the castings produced by
con+entional casting techni<ue showed a lesser +ertical marginal discrepancy and surface
roughness +alues than the castings produced using accelerated casting techni<ue. The castings
made with 'nlay 3a@ ha+e lesser marginal discrepancy and lower surface roughness +alues
when compared with the Pattern Resin.
Papadopoulos and A@elsson reported a superior fit of crowns on dies if phosphate)bonded
in+estment moulds were prepared with longer burn out schedulesL marginal gaps were 6 times
greater with shorter burn out schedules.
00
5onger burn out cycles as recommended by
manufacturer were used in this study and was probably the reason for lesser +ertical marginal
discrepancy and surface roughness +alues of castings made by con+entional casting techni<ue as
compared to the castings produced using accelerated casting techni<ue. Though the marginal
discrepancy and surface roughness due to accelerated casting techni<ue is significantly larger
than the con+entional casting techni<ue in the study, the mean marginal discrepancy of 22.7. >m
# 28.:8 >m obtained by accelerated casting techni<ue with 'nlay 3a@ and Pattern Resin in this
study is with in the clinically acceptable limits. Accelerated techni<ues may take ad+antage of
characteristic e@othermal setting reaction of phosphate)bonded in+estments. eat)enhanced
setting e@pansion continues uninterrupted as the mold is transferred into a preheated furnace for
thermal e@pansion.
0,
This may probably be the reason for the marginal discrepancy and surface
roughness of cast copings by accelerated techni<ue to be with in the clinically acceptable limit.
'n this study two types of pattern materials, 'nlay 3a@ and Pattern Resin were used. Most
of the studies by Schneider,
77
/ailey and Sherrard
7,
deal pattern resin with intra coronal
restorations =post # core?. Alan 'glesias MS
72
compared the marginal discrepancy of both intra
coronal and e@tra coronal restorations using inlay wa@, auto polymeriAed acrylic resin and two
types of light polymeriAed resin pattern materials. The results showed that light polymeriAed
resin pattern was superior with less marginal discrepancy than other two materials. The author
compares the incremental and bulk addition techni<ues, in which incremental techni<ue
produced smaller marginal discrepancy than the bulk techni<ues.
The result of this study is correlated with Alan 'glesias study.
72
The results showed that
marginal discrepancy was minimal for 'nlay 3a@ when compared with the auto polymeriAed
resin pattern with the bulk techni<ue for e@tra coronal restorations. The auto polymeriAed resin
pattern due to high polymeriAation shrinkage has greater marginal discrepancy when compared
with the wa@.
Accelerated casting techni<ue has greater marginal discrepancy when compared with
the con+entional casting techni<ue. This may be due to bulk addition of the material. Most of the
literature on accelerated casting techni<ue shows better marginal fit with intra)coronal
restorations. ow e+er further research to be done on the e@tra)coronal restorations.
'n this study the surface roughness of resin pattern is greater than the 'nlay 3a@. This
may be due to the greater siAe of the polymer beads =appro@imately 06->m?
29
and also due to
e+aporation of the monomer which could not be controlled.
The specimens are fabricated with a bulk techni<ue and smoothening of the surfaces was
not possible as it would increase the desired standardiAed thickness of -.6mm. The surfactant
which is used to decrease the surface tension and contact angle probably has the little effect in
impro+ing the contact of the in+estment with the pattern.
Due to rapid heating in the accelerated casting techni<ue there is sudden production of
steam with in the in+estment that carries some of the salts and modifiers on to the inner wall of
the mold space. After e+aporation of the steam, these modifiers settle on the inner surface of the
mold and are responsible for increase in surface roughness in accelerated casting techni<ue.
Due to greater surface roughness on Pattern Resin it can be mostly used for
ceramometal restorations. The greater the surface roughnessL better will be the mechanical
bonding.
Accelerated casting techni<ues using phosphate)bonded in+estments are considered to
ha+e some desirable ad+antages. 1n<uestionably time is sa+ed. Past in+estigations make it
apparent that, within commercially a+ailable phosphate)bonded in+estments, dissimilar
performance characters are e@pected. This knowledge suggests that casting techni<ues should be
studied with broad sample of alloys and phosphate)bonded in+estments, considering the
possibility that there may be an optimum combination in each situation.
The results of this study encourage further research with accelerated techni<ue and
reinforce the need to identify the factors that facilitate better marginal fit and surface roughness
of cast restorations. $nly one single wa@ pattern is in+estigated per casting in this study. The
performance of the described accelerated casting techni<ue when more than one wa@ pattern or
fi@ed partial dentures in+ested in the same ring re<uires further in+estigation. 4our
predetermined points were used to record the marginal gaps in this study. More number of
reference points for marginal gap measurements for each coping may yield a better confirmati+e
result. An :-O special li<uid was used in this study. A further e+aluation of different special
li<uid to distilled water ratios on the marginal gaps and surface roughness of cast restorations
help to impro+e the outcome of this study. A further in+estigation on the influence of surface
roughness of dental casting affecting the marginal fit and the time re<uired to finish and polish
the base metal cast restoration will enhance the outcome of these procedures. 4urther studies
which incorporate the abo+e considerations are re<uired to enhance the results obtained with this
study.

Su$$ary ) Con-lusion
This study has been done to e+aluate and compare the +ertical marginal
discrepancy and surface roughness of cast copings made by two different casting
techni<ues with two different materials. The four techni<ues used in the study were,
con+entional casting techni<ue of 'nlay 3a@ copings with 7 stage burnout procedure =")
'?, accelerated casting techni<ue of 'nlay 3a@ copings with single stage burnout
procedure =")''?, con+entional casting techni<ue of Pattern Resin copings with 7 stage
burnout procedure =")'''? and accelerated casting techni<ue of Pattern Resin copings
with single stage burnout procedure =")'(?.
A total of ,- 'nlay 3a@ copings, ,- Pattern Resin copings were fabricated with
stainless steel master die and former assembly, and di+ided into 2 groups with 0-
specimens for each techni<ue. A phosphate bonded in+estment was used to in+est all
'nlay 3a@ and Pattern Resin copings with :-O special li<uid in a metal ring with
ceramic ring liner. Specific burn out cycles were followed according to each techni<ue
and all the samples were cast in nickel chromium alloy in induction casting machine. The
cast copings obtained were sand blasted. The internal surface was inspected and finishing
procedures done. The copings were seated on the stainless steel die with finger pressure
till the resistance obtained and +ertical marginal discrepancy measurements were
recorded using a photo microscope. The results obtained were statistically analyAed.
A custom made stainless steel coping holder was used for measurement of
surface roughness to make the coping perpendicular to the surface roughness analyAer.
The surface roughness measurements were recorded using computer controlled surface
roughness analyAer. The results obtained were statistically analyAed.
The +ertical marginal discrepancy of cast copings obtained by accelerated casting
techni<ue showed a significantly higher +alue as compared to those obtained by
con+entional casting techni<ueL cast copings obtained by Pattern Resin showed a
significantly higher +alue as compared to those obtained by 'nlay 3a@. The mean +ertical
marginal discrepancies of all the copings obtained by the four techni<ues were within
clinically acceptable limit.
8
The surface roughness of cast copings obtained by accelerated casting techni<ue
showed a significantly higher +alue as compared to those obtained by con+entional
casting techni<ueL cast copings obtained by Pattern Resin showed a significantly higher
+alue as compared to those obtained by 'nlay 3a@. The mean surface roughness of all the
copings obtained by the four techni<ues was within clinically acceptable limit.
.
The following conclusions were drawn from the data obtained in this study of
comparati+e e+aluation of the +ertical marginal discrepancy and surface roughness of
cast copings obtained by con+entional and accelerated casting techni<ues using two
different pattern materials * an in+itro study.
0. The order of discrepancy +alues of +ertical marginal discrepancy of the cast copings in
this study is as followsC
a. 5east marginal discrepancy ) con+entional casting techni<ue of 'nlay 3a@ copings
with 7 stage burn out procedure =")'? ) 72.-, >m.
b. Moderate marginal discrepancy ) con+entional casting techni<ue of Pattern Resin
copings with 7 stage burn out procedure =")'''? ) 79.-8 >m.
c. Ma@imum marginal discrepancy ) accelerated casting techni<ue of 'nlay 3a@
copings with single stage burn out procedure =")''? ) 22.7. >m and accelerated casting
techni<ue of Pattern Resin copings with single stage burn out procedure =")'(? ) 28.:8
>m.
,. The order of roughness +alues of surface roughness of the cast copings in this study is as
followsC
a. 5east surface roughness ) con+entional casting techni<ue of 'nlay 3a@ copings with 7 stage
burn out procedure =")'? ) 2.7:>m
b. Moderate surface roughness ) accelerated casting techni<ue of 'nlay 3a@ copings with
single stage burn out procedure =")''? ) 6.20 >m
c. Ma@imum surface roughness ) con+entional casting techni<ue of Pattern Resin copings
with 7 stage burn out procedure =")'''? )9.:- >m and accelerated casting techni<ue of Pattern
Resin copings with single stage burn out procedure =")'(? ) ..,2 >m.
7. The mean +ertical marginal discrepancy and surface roughness of all the cast copings obtained
by the four techni<ues =")', ")'', ")''' and ")'(? were within the clinically acceptable limits.



*i,liogra+hy
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+ersus marginal gaps as determined by pre)doctoral students and prosthodontists.
N Prosthodont. ,--6L 02=2?C ,,8),7,.
2. L-A*)r>)< P= C)r*7/)r7 A= A+)r/,B ME= T--03)C,r RW. Dimensional accuracy
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,---L :2C ,9)70.
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function of the marginal gap. N Prosthet Dent. 0..0L 86=7?C 278)22,.
(. B,>. A= M.53)+)C.< EG= H.r)B)A) H= S0)rC PC. The effect of different in+estment
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$. R7>> ED= M)rr-@ RM= E.<<A)// HF. Dental 5aboratory Procedures. (ol ,.
St.5ouisL The &.(. Mosby &ompanyC 0.:8C ,07),,-.
%. C--/,B ?P= D-B+, TM= C)270- AA. Surface smoothness and marginal fit with
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preparations on the marginal seal and occlusal seat of full crown preparations. N Prosthet
Dent. 0.:0L 26=,?C 07:)026.
(. OD7r) H= R)20.< CN= A<D)r E. 'nner surface roughness of complete cast crowns
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Prosthet Dent. 0.:,L 29=0?C 87)8:.
20. L)5B AM= F7C7. H= ?,/>r,<,/ M. Three factors affecting in+estment setting
e@pansion and casting siAe. N Prosthet Dent. 0.:7L 2.=0?C 6,)6:.
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Prosthet Dent. 0.:7L 6-=6?C 860)867.
22. M)r<)@ FA= R.HC WG= H,<*B RA= H./A)/ RW= P,++,r7 GB. 'nternal +olumetric
e@pansion of casting in+estments. N Prosthet Dent. 0.:2L 6,=7?C 780)788.
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function of the marginal gap. N Prosthet Dent. 0..0L 86C 278)2,.
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79.
$(. Gr-0,/ M= AJA)// D= Pr-*<0,r L= W,*,r H. Determination of the minimum
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Dent. ,---L :7=0?C 2-)2..
$9. U<3.@)0) O= M-r),< ?V= B-00./- MA= S.+8) EG. Marginal fit of nickel)chromium
copings before and after internal adBustments with duplicated stone dies and disclosing
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%0. AB)> MF. &ompositional stability and marginal accuracy of complete cast crowns
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%. I0- M= E7r-.@) A= N)D)<)@) S= Y-<3.>) T= Y)D)<)C. H= O<3.>) Y. !ffect of wa@
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%2. B,FF-/ OL= P,>r)FF. H= I)/.67,++. O= S.+8) TBC. !ffect of casting techni<ue on
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%$. G)<<./- G= M-/;r./ SB= S5)/7 M= S2./) G. Marginal adaptation of fi@ed
prosthodonticsC A new in +itro 78-)degree e@ternal e@amination procedure. 'nt N
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%%. M.+)/ FM= C-/<)/. S= S-*r./3- LC= S./3-r,0. MAC= S-7<)-N,0- MD= E/-@+,<
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crowns. /raA Dent N. ,--2L 06=,?C 0,9)07,.
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Prosthodontic Society. ,--6L 6=7?C 028)060.
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Wuintessence 'nt ,--9L 7:=6?C ,90),9:.
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Wuintessence Publishing &o, 'ncL 0..9L 786)7:7.
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