NEW TECHNOLOGY

Advancements in Casting Technology:

Rapid Burnout Investments

Nannette Boyd, CDT*

Brian J. Knopf, BS Chem. MBA*"

burnout investments have

evolved in response to the laboratory's need to reduce processing and
technician time. The new generation of
phosphate investments can produce superb
castings in minimal time. However, all phosphate investments are sensitive to the investing technique. Rapid burnout investments
are typically even more sensitive to technique due to the more reactive nature of the
chemical system. A knowledge of phosphate
investment chemistry and the rapid burnout
investment technique will improve the dental
technician's success when using a rapid
burnout investment. This article provides a
discourse on the chemistry and composition
of phosphate investments and outlines the
rapid burnout technique using FastFire 15 investment (Whip Mix Corp, Louisville, KY).

Technical Reprsentative, Whip Mix Corporation, Louisville,

Kentucky.
**Vice President of Lab Sen/ices, Whip Mix Corporation,
Louisville, Kentucky,
Reprint requests: Ms Nannette Boyd, Whip Mix Corporation,
361 Farmington Avenue, PO Box 17183, Louisville, KY4021?.

Phosphate Investment
Most laboratories in the United States use
phosphate investment for all alloysprecious and nonprecious. The main advantage
of phosphate over gypsum investment is that
it can withstand the much higher heating required for non-gold and low-gold alloys as
well as ceramics. Expansion can also be adjusted with the colloidal silica liquid. As a result, phosphate investments are compatible
with many different alloys and ceramics.
The phosphate investment binder chemistry is fairly complex and results in a very
energetic reaction. Ammonium phosphate
and magnesium oxide react in the presence
of water to form an ammonium magnesium
phosphate compound. This is an aggressive
reaction that generates a great deal of heatSome investments will even produce steam
during the set. When heated above 850C
during burnout, the end product is primarily
magnesium pyrophosphate (based on x-ray
diffraction rate), which is a strong crystalline
complex. The basic chemistry is as follows:
NH.HjPO, + MgO + 5Hfi - NH.MgPO, Hp
6H;O {plus heat) - M g / j O , (plus water)
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A typical phosphate investment system

consists of three key components:
1.

Binder. The binder system consists primarily of ammonium phosphate and

magnesium oxide. As stated before,
this is a very energetic reaction and the
kinetics of this reaction are crucial to
casting quality. Other chemicals are typically added to control the reaction at
key stages.
2. Refractory. The refractory system is primarily quartz and another allotrope of
silica called cristobalite. Other refractory
oxides may be used to some extent.
When developing the refractory system,
the consistency or feel of the mix, thermal expansion of the investment, and
density or porosity requirements are
taken into consideration.
3. Liquid. The liquid contains colloidal silica, which contributes to the setting and
thermal expansion. Unlike a gypsum investment, the casting size can be controlled by the use of the proper concentration of liquid.
The binder system is the most important
component in a phosphate investment because it can have the greatest effect on the
overall investment performance. It is even
more important in the rapid burnout investments. The binder chemistry can affect all of
the main properties that are considered important for an investment:

Setting time
Setting expansion
Strength
Thermal expansion
Pattern expansion
Cracking and spalling
Casting size

Though the refractory system is important,

it tends to be more stable and less sensitive
to external factors. The refractory system can
affect:
Fluidity or feel of the mix (ie, whether it
feels coarse or smooth, thick or thin)
Thermal expansion
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Density or porosity, which will impact

cracking and spalling
Casting size
Many technicians think that thermal or setting expansion will dictate the casting size.
This is not so. After analyzing hundreds of
data points, the authors have found a statistically poor correlation between thermal or
setting expansion and casting size. The reason is that there is a third componentpattern expansionthat must be considered.
Pattern expansion is the expansion that occurs as the wax pattern is heated during the
initial stage of the binder reaction before the
investment has fully set. If the investment
sets before sufficient heating, the casting will
have a tight fit. If the pattern heats too much
before the set, the casting will be loose and
may have a rough surface.
Without knowledge of the pattern expansion (which we cannot measure), there is not
enough information to predict casting size
without making castings. An understanding
of the factors that affect the binder reaction
should help the technician overcome problems with casting fit and finish.

Factors Affecting Binder Reaction

Before the mold fully sets, phosphate investments are sensitive to changes such as the
addition or removal of energy from the investment, or activities that affect the crystal
growth. As a result, phosphate investments
are sensitive to the preparation technique.
Variations in mixing time or mixing speed, or
the temperature of the equipment, can add
or subtract energy, which can slow or accelerate the reaction. To demonstrate this, setting expansion gauges, made from both
metal and plastic, were equipped with a
transducer and a thermocouple linked to a
computer to monitor the setting expansion
and temperature profile. It was found that
the metal setting-expansion gauge, which
absorbs heat better than plastic, removed
energy from the investment and slowed the
reaction. This delayed the setting time, re-

RAPID BURNOUT INVESTMENTS

Fig 1 Time from investing t o casting with rapid comared to standard investment.

duced the maximum temperature ofthe reaction, and greatly reduced the setting expansion. This experiment emphasizes the
need for a stable casting environment and
consistent casting technique. It also shows
that an investment may perform differently in
a metal ring than in a plastic or paper ring.
Phosphate investments are also sensitive
to environmental conditions. Since the investment contains chemicals that react aggressively in the presence of water, it is clear
that any moisture can affect the product.
Bulk powder should not be exposed to moisture or humidity. Individual envelopes provide much better security.
Many liquids also are not freeze stable and
may freeze during shipping. Even freezestable liquids can only withstand a limited
number of freeze/thaw cycles. Liquid should
not be used if any of it has jelled or solids
are present in it.
To achieve optimum performance, one
should always start by following the manufacturer's instructions. If the desired performance is not achieved, the mixing technique or energy management system may
be responsible; most likely the system
being used is different from that of the
manufacturer. Mixing for more or less time,
or heating or cooling the system, should be
tried. Periodically evaluating the mixing
bowl against a standard is also suggested,
as the authors have found that a worn bowl
and a new bowl will give different casting
results.

Most laboratories in the US have switched

from the ring technique to the ringless technique for phosphate investment casting. The
investment slurry is poured into a plastic or
paper liner that is removed before burnout.
The ringless technique is considered to be
cleaner to work with and easier to divest.
However, investments designed for the ring
technique may not work in the ringless technique. Investments may be more prone to
cracking without the extra support from the
metal ring.

Rapid Burnout Investment

The most significant advance in crown and
bridge investments has been the development of the rapid burnout technique. With
this technique, the bench-set time is shortened and the mold is placed directly into a
heated furnace. From a manufacturer's perspective, these conditions present a special
challenge. The short bench-set time and
rapid heating put extreme stress on the
mold. As a result, the binder chemistry and
refractory system density become even more
important. Dental laboratories are increasingly demanding this type of investment. The
reason is simple: time = money.
Figure 1 shows the typical difference in time
between the rapid burnout and standard casting techniques. The bench-set time is reduced
from about 45 to 15 minutes for the fastest investments. The standard heating cycle, where
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Fig 2 FastFire 15 investment

system.
Fig 3 Sprues are attached to wax
patterns using pliable sticky wax.

Fig 4 Patterns mounted in

crucible former base are sprayed
with Whip Mix SmoQthex wax
pattern cleaner.
Fig 5
base.

Table 1

Ring is placed on former

Suggested Liquid Concentrations for Mixing*

Alloy

Liquid
concentration

lmLyOg

Liquid/powder ratio
24 mL/90 g
27mL/100g

Base
(Ni-Cr, Ni-Cr-Be)

90%

14 mL liquid
2 mL water

21 mL liquid
3 mL water

23 mL liquid
4 m L water

Noble
(Ag-Pd, Au<40%)

75%

12 mL liquid
4 m L water

18 mL liquid
6 m L water

20 mL liquid
7 m L water

High Noble
(Pd with 2% to 8% /
Au>40%)

60%

10 mL liquid
6 mL water

14 mL liquid
10 mL water

16 mL liquid
11 m L water

"Recommended concentrations are approximate and can be adiusted to optimize fit. To increase ex
pansion, use more liquid and less water. To decrease expansion, use less liquid and more water. Always maintain total liquid/water volume.

the mold is placed in an oven at room temperature and slowly heated to maximum temperature, is eliminated. The mold is placed directly into an oven at maximum temperature
and allowed to soak for approximately 30 minutes. The rapid burnout technique reduces this
stage of the casting operation from about 2
hours to 40 minutes. The time from the start of
investing to the completion of casting is less
than 1 hour. This results in more casting per
day and less processing time. It is also of value
for accommodating rush orders.
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QDT 1998

Rapid Burnout Investment Technique

The following technique outlines the rapid
burnout process using FastFire 15 investment. FastFire 15 is a fine-grain phosphate
investment that requires only a 15-minute
bench set before placing molds into a hot
oven for rapid burnout. It may be used with
either the ringless or metal ring technique.
Optimum fit is achieved for all crown and
bridge alloys through dilution of the freezestable FastFire liquicJ (Fig 2).

RAPID BURNOUT INVESTMENTS

Fig 6 Powder s incorporated

into liquid by hand spatulation.
Fig 7 Investment is mixed under
vacuum at low speed.

Fig 8 Casting ring Is filled using

low vibration.
Fig 9 Wax patterns are covered
with no less than 0.25inch (7 mm]
of investment.

Preparation

Fill casting ring using low vibration, covering wax patterns with no less than 0.25
inch (7 mm) of investment (Figs 8 and 9).

Attach sprue to the wax pattern using pliable sticky wax (Fig 3).
Mount patterns on crucible former base.
Spray with Whip Mix Smoothex wax pattern cleaner. Gently blow excess cleaner
from pattern (Fig 4).
Place ring onto former base (Fig 5).

Bench set 15 minutes, then remove mold

from ring and base (Fig 10).

Mixing

Burnout

Prepare liquid at suggested concentration

shown in Table 1, Distilled water is recommended for dilution.
Rinse the bowl with water and shake out
excess.
Add measured liquid to mixing bowl. Incorporate powder by hand spatulation 10
to 15 seconds (Fig ).
' Mechanically mix under vacuum at low
speed (350 to 450 rpm) from 60 to 90 seconds (Fig 7).

Trim glaze off top of mold and rinse

under tap water (Fig 11). Note: Molds allowed to set more than 24 hours should
be re-wet by soaking in water for 3 to 5
minutes.
Place mold in preheated oven at recommended temperature (maximum 900C/
1650T), For higher temperatures, place
mold in oven at 900C (1650F), then heat
to final temperature at 14 to 20C {25 to
40F) per minute (Fig 12).

Bench Set

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Fig 10 Mold is removed from the ring and base

after bench set.
Fig 11 Glaze is trimmed off top of mold then rinsed
under tap water.
Fig 12 Mold is placed in preheated oven at
maximum temperature of 900C 150T).
Fig 13 Casting is done according to alloy
manufacturer's instructions.
Fig 14 Investment is broken from metal
framework/castings.
Figs 15a and 15b Metal is prepared for porcelain
application with separating disk and noncontaminating aluminum oxide abrasives.
Fig 16 Completed castings on master cast ready for
porcelain application.

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RAPID BURNOUT INVESTMENTS

Heat soak at final temperature for 30 minutes; add 10 minutes per additional
mold.

Casting

Table 2 Physical Properties of FastFire 15

Investment*
Liquid/powder ratio

7-9 min

Setting expansion

1.0%

Thermal expansion

Cast according to alloy manufacturer's instructions (Fig 13).

27mLyiOOg

Initial setting time

Compressive strength, wet

(45 mm)

1.0%
500 psi (3.4 MPa) .

Measured at 100% liquid concentration.

De vesting

Conclusion
Break investment from metal framework/
castings (Fig 14).
Clean castings according to alloy manufacturer's suggestions (aluminum oxide 50 to
60 ^im or ultrasonic solution}.
Using a separating disk and noncontaminating aluminum oxide abrasives, prepare
metal for porcelain application (Figs 15a
and 15b).
Place completed castings on master cast
for porcelain application (Fig 16).

Rapid burnout investments can provide excellent castings in minimal time. The physical
properties of the FastFire 15 investment system are shown in Table 2. A knowledge of
phosphate investment chemistry and the investing technique will enable the technician
to ensure better control over the casting
process and take full advantage of the benefits from the new generation of rapid burnout
investments.

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