Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
MORNING
BY
Ramesh d, Maharjan
CDT
CONTENTS
INTRODUCTION
DEFINITIONS
HISTORY
STAGES OF CASTING PROCEDURE:
INTRODUCTION
technique.
We are going to know the exact influence of each variable in the
DEFINITIONS
6) CASTABILITY:
HISTORY
Lost Wax Method dates back to atleast 4th millenium B.C.
Dental casting procedures have originated from Black smithery
10
11
Cast his bronze masterpiece Perseus & the Head of Medusa using
13
Gold melted with a blowpipe was then forced into the plaster
Blowpipe
Compressed ai
cylinder
Inlay Mold
14
was greatly inhibited by metal casting ring & advocated lining the
15
ring with soft asbestos.
casting .
16
17
equipment .
1989 - H. Hamanaka, H. Doi et al devised a new casting machine for
18
CLINICAL STEPS:
19
crown
Occlusal bevel 30-45 degrees to long axis of crown on outer
plane of walls.
Flat pulpal floor
Axial wall Flat or slightly rounded in bucco-lingual direction
Gingival floor Flat in bucco-lingual direction
20
2. MAKING OF IMPRESSION
Impression of the prepared tooth structure.
Indirect technique fabricating cast restorations.
preparation
Dulplicate surface anatomy of adjacent & opposing teeth.
Duplicate surface anatomy of adjacent soft tissues.
21
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(or)
The positive reproduction of the impression involving only the prepared tooth for
the processing of inlays or bridge structures.
23
ADVANTAGES:
Easy to use
Inexpensive
Compatible with most of the impression materials.
24
TYPE V IMPROVED
STONE
25
reduce its S.E. < 0.1% & to reduce the diameter of the die.
GYPSUM DIES ARE SOMETIMES MODIFIED:
Make more abrasion resistant.
Change the dimensions of the dies.
Increase the refractoriness of the dies.
26
DIE HARDENERS
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D) DIE LUBRICANTS:
To avoid sticking of wax pattern to die.
INDICATIONS:
- Easy removal of casting from die.
28
E) DIE SPACER:
To produce relief space for cement.
Film thickness- 25microns
Applied in several coats to within 0.5mm of the
30
4. WAX PATTERN
PREPARATION
1st procedure in the casting of an inlay or crown for the lost-wax
Association Sp No 4:
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32
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PARAFFIN WAX
-40-60%
Derived from high boiling fractions of petroleum
Complex mixture of hydrocarbons of methane series & Amorphous
or Microcrystalline phases .
Type I always paraffin- high melting point.
DISADVANTAGES:
Flakes when it is trimmed
No smooth, glossy surface.
34
GUM DAMMAR
Natural resin
Improves the smoothness in molding
Increased resistance to cracking and flaking
Increases toughness
Enhances smoothness and lusture of the surface.
35
CARNAUBA WAX
Fine powder leaves of tropical palms .
Hard
High melting point
Decreases the flow at oral temperature
Agreeable odour
Contributes to the glossiness of wax surface
Replacements of Carnauba wax :
Complex nitrogen derivatives of higher fatty acids
Esters of acids derived from montan wax .
36
CANDELILLA WAX
Partially or entirely replace carnauba wax.
CERESIN
Modify Toughness & Carving characteristics of the
wax.
37
the die.
ANSI/ADA Sp.No: 4
Melted wax when vapourised at 500C (932F) shall leave no residue in
38
C) FLOW
Type I 37C (98F) is 1%
Type II 9%
Minimizes distortion of a well Carved pattern as it is withdrawn
39
D) THERMAL PROPERTIES
Low thermal conductivity More time is required to both heat them
uniformly and cool them to body temperature .
Thermal expansion data :
41
Temperature at which
E. MANIPULATION
Methods of softening wax :
1. Best method Controlled temperature oven .
Why ? Since its a poor thermal conductor , a controlled heating
device for a prolonged period ensures uniform softening .
2 . Dry heat FLAME is preferred
- Twirled in the flame ? Always quick heating tends to melt the only
the superficial layer . So , this will bring inner surface out Vice
versa .
- Repeat till the wax is warm all over .
- Knead it and shape it the prepared cavity .
43
4 . Swaging The die and the softened wax in the die are
mounted into a closed vessel containing water and a piston . When
pressed , hydrostatic pressure is evenly applied over the pattern
to adapt it to the cavity .
44
According to Marzouk:
1. Formulation of a wax pattern by carving Wax is overfilled &
carved.
2. Incremental build-up of the wax pattern
3. Direct wax pattern
4. Anatomic core wax pattern
45
F. WAXING INSTRUMENTS
Large increments
Smaller increments
46
Technique :
- Heat the instrument .
- Touch the wax .
- Quickly reheat the shank
47
G. CARVING
Sharp instruments .
And never heat it
Use light pressure .
Always overfill and carve.
Hold the carvers partly over the remaining tooth structure and
complete the carving with this guide .
48
PKT No 4
NO 2 WARD
CARVERS
PKT No 5
49
H. BURNISHING
- Slightly warm a blunt instrument and rub the wax , not as hot as it
melts .
- Less effective than carving but easier to control and leaves a
smoother surface ( esp. near margins ).
-Final polish with a silk cloth .
- In inaccessible areas , cotton wrapped around a toothpick .
50
PKT
No 3
51
- In a MOD use a staple pin . Fasten it and insert a floss and hook it .
-Avoid finger contact it may produce a temperature rise .
INDIRECT PATTERNS:
- Lubricate the die
- Sheet of washed rubber dam increases friction & aids removal.
- Right hand fingers hold pattern & left hand die die pulled from
52
pattern by bending fingers of left hand.
53
SOLUTION
- Softening the wax uniformly by heating at 50 degrees for 15 min.
- Warmed carving instruments and a warmed die .
- Adding wax in small amounts .
LOWER STORAGE TEMPERATURE :
- If a wax pattern is allowed to stand uninvested for longer than 30
Min Keep it in a refrigerator Distortion is less in lower
temperature.
- It should be warmed to room temperature before investing .
54
5. SPRUE FORMER
MOLD: A negative form in which an object is cast/shaped.
SPRUE: The mold channel through which molten metal flows into
the mold.
(or)
A Sprue is a channel in a refractory investment through mold through
which molten metal flows.
55
56
type & size of wax pattern, type of casting machine & type of flask
or casting ring used.
57
C. TYPE OF SPRUE
FORMER
Wax
Plastic/Resin
Metal sprues
58
59
In conjunction with the pressure of the casting machine & density of the molten metal, controls the rate & flow of
2.5 mm Crowns
60
E. SPRUE POSITION
Prefer At the occlusal surface
(or)
61
F. SPRUE ATTACHMENT
Asgar & Peyton (1959) Flaring should occur at Sprue/wax pattern
junction.
Flared for High density alloys.
Often restricted for lower density alloys.
Best for the molten alloy to flow from thick section to surrounding
62
63
64
More than 6 mm
The gold will solidify before the
entrapped air can escape , resulting in
rounded margins , incomplete casting ,
66
H. SPRUE DIRECTION
Shd be directed away from any thin or delicate parts of pattern
67
I. RESERVOIR
The reservoir is placed approximately 1.5mm from the pattern .
- Diameter should be greater than the bulkiest portion of the sprue .
Function Prevents localized shrinkage porosity .
- Because of the large mass of alloy and position in the heat centre of
the ring , the reservoir will remain molten to furnish liquid alloy into
the Mold as it solidifies .
- Resulting shrinkage will occur in the reservoir bar rather than the
restorations.
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Reservoir
70
J. CRUCIBLE FORMER
Funnel shaped.
Rubber, metallic or plastic.
Connected to sprue in same was as sprue attached to mold.
Wax pattern with sprue former is attached to crucible former in a
71
SPRUING
DIRECT SPRUING
When two thick portions of wax are separated by thin wax, then
2 separate sprues should be attached using direct spruing.
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73
INDIRECT SPRUING
Indirect spruing uses the same basic principles of spruing. But the
only difference lies in attachment of 3 running horizontal bars.
The whole indirect sprue complex consist of 3 parts:
Manifold sprue.
Horizontal running bar.
Feeder sprue.
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6. CASTING RING
-Investment material is poured in the
casting ring & allowed to set around
wax pattern.
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POWERCAST RINGLESS
SYSTEM
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- The use of
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7. INVESTING
PROCEDURE
83
A. WETTING AGENTS or
DEBUBBLIZERS
Wax surfaces are not easily wetted by water
-If not covered by investment will develop surface irregularities in
casting .
- Wettax- mild soap solution.
-These agents reduce the surface tension of the wax pattern ,
promotes better wetting of the surface .
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MANIPULATION
- Paint the debublizing solution on the pattern .
- Gentle air dry
- Dont soak or rinse in water
- Dont allow pooling in internal line angles of the pattern
.
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B.
INVESTMENT MATERIALS
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GYPSUM BONDED
INVESTMENT
MATERIALS
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90
BINDER: 30 to 35 %
Alpha hemihydrate form of gypsum OR Dental Stone.
MODIFIERS:
5%
Casting
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ii) CLASSIFICATION:
Acc. To ADA Sp.no: 2- Casting Investments for dental gold alloys.
TYPE I Inlays & Crowns Thermal expansion
TYPEII Inlays & Crowns Hygroscopic expansion
TYPE III Partial dentures with gold alloys.
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1. NORMAL SETTING EXPANSION- A mixture of silica and calcinated gypsum (calcium sulphate
hemihydrate) results in setting expansion greater than that of the
gypsum product used alone.
- Silica particles probably interfere with the intermeshing and
interlocking of the cystals as they form thrust of the crystals is
outward during growth increase expansion.
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95
2. HYGROSCOPIC EXPANSION
When gypsum products are allowed to set in contact with water, it
leads to outward growth of crystals expansion which is greater in
magnitude than normal setting expansion.
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FACTORS AFECTING
Effect
Effect
Effect
Effect
Effect
Effect
Effect
Effect
of
of
of
of
of
of
of
of
HSE
composition
W:P Ratio
Temperature
time of immersion
Spatulation
Shelf Life of Investment
Confinement
the Amount of Added water.
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3. THERMAL EXPANSION:
Achieved by placing the mould in a furnace not greater than 700
C.
ANSI / ADA Specification No.2 requires that the thermal
expansion of
Type II investments be between 0% and 0.6% at 500 C.
For Type I investments, which rely principally on thermal
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v) STRENGTH:
- Compressive strength for the inlay investments should not be less
than 2.4 MPa when tested 2 hrs after setting.
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vii) POROSITY:
The more gypsum crystals that are present in the set investment, the
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102
E. PROPERTIES:
i) TYPES:
TYPE I For inlays, crowns and other fixed restorations.
TYPE II- For partial dentures and other cast, removable restorations.
ii) COMPOSITION:
POWDER- Ammonium diacid phosphate (NH 4 H2 PO4)
Silica Refractory
Magnesium oxide- reacts with phosphate ions.
LIQUID- In the form of silica sol in water.
iv) SETTING EXPANSIONWith use of full strength liquid, about 0.4% attained.
Hygroscopic technique 0.6%- 0.8% can be realized.
liquid and
water.
1% to 1.2% Use of undiluted liquid.
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v) ADVANTAGES:
Easy to handle without breaking before they are placed in a
vi) DISADVANTAGES :
When used with higher melting alloys, those with casting
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107
F. PROPERTIES:
Silica is the binder.
THERMAL EXPANSION- 1.5% to 1.8% can be attained between room temperature and
1000C to 1177 C.
108
ADVANTAGES :
alloys.
Good surface finishes, low distortion and high thermal expansion
(good fit).
Thin sections with fine detail.
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DISADVANTAGES:
Added processing attention and the extra precaution needed in
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111
HAND INVESTING
- Water is added first slow addition of powder to remove air from
powder.
-Hand spatulate the mix to incorporate the powder quickly.
- Cover of the bowlmechanical mixer mixed by hand.
- Coat the wax pattern with the investment
- Carefully coat the internal surface & the margin of the pattern
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VACUUM INVESTING
METHOD
-First hand spatulate the mix
-Attach the vacuum hose & mix
accordingly to the manufacturers
recommendations
-Invert the bowl & fill the ring
under vibration
-Remove the vacuum hose before
setting of the mixer
- Immediately clean the bowl &
mixing blade under running water
114
H.SETTING OF
INVESTMENT
It can be:
-In open air
-Hygroscopic technique
-Controlled water added technique
115
IN OPEN AIR
116
HYGROSCOPIC TECHNIQUE
- Once the casting ring is poured it is immersed into a water bath at
38 degrees temperature immediately.
- This can be altered by:
-W:P ratio
W:P HSE
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118
material.
Investment set min. 1 hr.
Ideally kept in oven when mold is wet.
Delayed for several hours kept in humidor.
Rubber crucible former removed.
Place the sprue hole down at first , for easy draining out of wax
Eliminated as a liquid .
Invert ring , for the oxygen in the oven atmosphere to circulate
more readily , to form gases rather than fine carbon which may
interfere with venting .
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120
123
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9. CASTING CRUCIBLES
3 types of casting crucibles are available : Clay, Carbon and Quartz
(Zircon alumina).
Clay crucible are many of crown bridge alloys such as high noble-
alloy.
Carbon crucible high noble crown bridge , higher fusing , gold
125
CARBON CRUCIBLES
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127
128
ELECTRICAL
Resistance
Induction
Direct Current Arc
Oxygen /Acetylene
129
TORCH MELTING
- The alloy is melted in a separate crucible by a torch flame and is
cast into the mold by centrifugal force.
-Temperature of gas-air flame is influenced by
i) Nature of the gas &
ii) Proportion of gas and air in the mixture.
-Considerable care Obtain a non-luminous brush flame, with
combustion zones clearly differentiated for melting the alloy .
130
ZONES OF A FLAME
Zone 1 Directly from the nozzle
Air and gas are mixed before
combustion .
No heat is present
Zone 2 Combustion zone
Gas & Air are partially burned
Color GREEN
131
Zone 3 :
Reducing zone
132
134
Disadvantages :
Excessive heat may distill lower melting components .
Overheating gases to dissolve in the casting
porosity
Highly technique sensitive
135
RESISTANCE HEATING
e
p
e
e
p
p
137
Advantages:
For metal ceramic prosthesis.
Base metals in trace amounts that tend to oxidize on
overheating.
Crucible located flush against casting ring.
139
140
141
142
143
pressure, or by vacuum.
It is more commonly used for melting base metal alloys,
more in jewelry .
Not been used for noble alloy casting as much as other
machines.
144
cathode
D
----------------------------------------
B
C
---------------------------------------anode
145
The temperature within the arc exceeds 4000oC and the alloy melts
very quickly.
This method has a high risk for over heating the alloy.
146
147
OBJECTIVES OF CASTING
148
TYPES
CENTRIFUGAL CASTING MACHINE:
The alloy is melted in separate crucible by a torch flame and the
metal is cast into the mold by centrifugal force.
149
150
CASTING TECHNIQUES
Spring loaded
torch melting
machine
Induction
melting
machine
Electrical
resistance
heated casting
machine
PNEUMATIC
151
ACCORDING TO SH SORATUR
1. Centrifugal casting machine
2. Steam Pressure machine-Solbrig machine
3. Air pressure machine Hereus
4. Spring wound Electrical resistance-melting
furnace-casting machine
5. Induction melting casting machine
152
vacuum.
Used for titanium and titanium alloys.
153
COMBILADOR CL-G 77
154
DEGUTRON
MEGAPULS 3000
155
156
157
158
The casting machine is given three (or) four clock wise turns and
159
160
PREHEATING CRUCIBLE
161
163
A reducing flux is used in melting the alloy (50% boric acid powder
and 50% fused borax ) it increases fluidity and reduces potential for
oxidation.
164
165
166
Once the metal fills the mold there is a hydrostatic pressure gradient
developed along the length of the casting.
The pressure gradient from the tip of the casting(0.21 to 0.28 Mpa/
30 to 40 psi) to the button surface is quite sharp and parabolic in
function, coming to zero at the button surface.
Because of this gradient there is also a gradient in the heat transfer
rate, such that the greatest rate of heat transfer to the mold is at the
high pressure end of the gradient (i.e. the tip of the casting).
Therefore, solidification progresses from tip to the button side.
The arm should be stopped with brake lever only when it gets slowed
down naturally and the ring is removed with casting tongs.
167
168
QUENCHING
After the casting has solidified, the ring is removed and quenched
169
ADVANTAGES OF QUENCHING
170
DIVESTING
Removal of Investment / Recovery of Casting.
171
172
CLEANING &
FINISHING THE
CASTING
12.
173
PICKLING
in an acid.
SOLUTIONS USED: 50% HCL, PHOSPHORIC ACID, HYDROFLUORIC ACID
-Advantages of HCl:
Aids in removal of residual investment as well as oxide coating
-Disadvantages:
Likely to corrode laboratory metal furnishings
Fumes are health hazard
-Method of cleaning :
Place the casting in test tube or dish and pour acid over it
- Other methods: Heating the casting and then dropping into the pickling
174
solution
175
SAND BLASTING
Casting is held in an sand blasting
of 100psi
Garnet
Ultrasonic cleaners
Abrasive spray devices
176
used.
- Rag or felt wheels impregnated with abrasives are used in the initial
phase of this stage.
- Final polishing is achieved using various oxides of tin and
aluminium used in conjunction with a small rag or chamois buffing
wheel, followed with an iron oxide rouge.
- Residual traces of rosin or waxlike matrix from oxides Polishing
compound remover followed by a hot, soapy water rinse.
177
CASTING
DEFECTS
3. POROSITY
I. Solidification defects
A. Localized shrinkage porosity
B. Microporosity
II. Trapped gases
A. Pinhole porosity
B. Gas inclusions
C. Subsurface porosity
III. Residual air
4. INCOMPLETE CASTING
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time.
181
Problems
Problems
Problems
Problems
Problems
Problems
Problems
Problems
with
with
with
with
with
with
with
with
accuracy
distortion
bubbles
surface roughness
fins on the surface or margins
short and rounded margins
miscasting
pits
182
183
1. DISTORTION
wax pattern
Setting and hygroscopic expansions of the investment may
whereas the solid occlusal bar of wax resists expansion during the
early stages of setting.
184
185
in shape.
Insufficient pressure during waxing- The pattern distorts
Create distortion.
TO AVOID DISTORTION
Appropriate selection of investing material with less setting
expansion
187
188
SURFACE ROUGHNESS
DEFINED: Relatively finely spaced surface imperfections whose height,
width, and direction establish the predominant surface pattern.
189
SURFACE IRREGULARITIES
190
a) AIR BUBBLES:
Inadequate vacuum or ineffective painting procedureVacuum must have at least 26mm mercury for vacuum investing.
Water/powder ratio - Investment is too thick, it will not cover the
pattern completely.
Excessive vibration of the ring- Produces small nodules.
NODULE
S
193
194
mixing
195
b) WATER FILMS:
Wax is repellent to water and if the investment becomes separated
from the wax pattern in some manner, a water film may form
irregularly over the surface.
Appears as minute ridges or veins on the surface.
Too high L/P ratios .
Pattern is slightly moved, or vibrated after investing or if the
197
c) RAPID HEATING
Result in formation of fins or spines on the surface of the casting
Due to the flaking of the investment when water or steam pours
198
TO
Prolonged heating-
investment fracture.
investment
199
heated.
200
d) UNDERHEATING
Incomplete elimination of wax residues may occur if the heating
time is too short or if insufficient air is available in the furnace.
Low-temperature investment techniques
Voids or porosity may occur in the casting from the gases formed
when the hot alloy comes in contact with the carbon residues.
Casting may be covered with a tenacious carbon coating that is
201
e)LIQUID/POWDER RATIO
to the pattern.
TO AVOID
202
Use the correct W/P ratio according to manufacturers instructions.
F)PROLONGED HEATING
TO AVOID
Thermal expansion technique is employed mold heated to the casting
203
If other fuel is used, special care should be observed that the color
204
h) CASTING PRESSURE
TO AVOID
a gauge pressure of 0.10 to 0.14 MPa in an air pressure casting
machine (or)
3 to 4 turns of spring in an average type of centrifugal casting
206
j) FOREIGN BODIES
When foreign substances get into the mold, a surface roughness may be
produced.
Rough crucible former with investment clinging bits of investment are carried
flux.
207
contamination
grey layer on the surface of gold alloys that is brittle and does not
clean readily during pickling.
208
TO AVOID
Proper Spruing To prevent the impact of molten metal at an
angle of
209
l) PATTERN POSITION
If several patterns are invested in the same ring, it causes
breakdown or cracking of the investment if the spacing between
the patterns are less than 3mm.
B/c expansion of wax is much greater than that of the investment.
TO AVOID
Do not place several patterns too close together if invested in the
same ring
Avoid too many patterns in the same plane in the mold
210
m) CARBON INCLUSIONS
carbon inclusions.
211
3. POROSITY
Not only does the internal porosity weaken the casting but if it also
212
the alloy
214
215
HOT SPOT:
A hot spot may retain a localized pool of molten metal after other
areas of the casting have solidified.
This in turn creates a shrinkage void, or suck-back porosity.
216
217
This decrease helps the molten alloy at the pulpal floor to solidify
218
MICROPOROSITY
Occurs from solidification shrinkage but is generally present in
fine-grain alloy castings when the solidification is too rapid for the
microvoids to segregate to the liquid pool.
219
porosity.
220
PINHOLE/GAS INCLUSION
POROSITY
221
porosity results.
222
SUBSURFACE POROSITY
at the first moment that the alloy freezes at the mold walls.
Short, thick sprue pin- Rapid entry of the alloy causes skin formation; the bulk
the investment will solidify and form a thin skin. The alloy behind it shrinks during
solidification and pulls away, forming small porosities.
223
ENTRAPPED-AIR POROSITY
- Occurs on the inner surface of the casting, sometimes referred to as
BACK-PRESSURE POROSITY large concave depressions
Caused by the inability of the air in the mold to escape through the
224
225
226
Thickness of the investment between the tip of the pattern and the
227
4. INCOMPLETE CASTING
Partially complete casting, or perhaps no casting at all, is found.
The obvious cause is that the molten alloy has been prevented, in
Two factors that may inhibit the ingress of the liquefied alloy are
228
229
suspected.
If insufficient casting pressure is used, the back pressure cannot be
overcome
230
Furthermore,
The mold is filled and the alloy is solidified in 1 sec or less; yet it is quite
point.
These failures are usually exemplified in rounded, incomplete margins.
231
ROUNDED INCOMPLETE
MARGNS
232
234
CONCLUSION
Thus, these are the various causes for the failure of the
castings and methods by which these defects can be
avoided, thereby producing a casting of good quality for
clinical success.
235
REFERENCES
1. PHILLIPSSCIENCE OF DENTAL MATERIALS11THEDITION
2. CRAIGS- RESTORATIVE DENTAL MATERIALS-12 TH
EDITION
3. OPERAIVE DENTISTRY MARZOUK
4. DENTAL MATERIALS & THEIR SELECTION
WILLIAM J.OBRIEN-3RD EDITION
5. CONTEMPORARY FIXED PROSTHODONTICSROSENSTIEL-4TH EDITION
236
THANK YOU
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