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CASTING DEFECTS

Content

Introduction
Classification of defect in casting/common causes of casting defects
Dimensional Inaccuracies or Dimensional errors in casting
Distortion
Surface roughnessSurface irregularities
Nodules
Fins
Ridges/Veins on casting surface
Discoloured castings
Pits(Inclusion porosity)
Incomplete casting
Porosity
Review of literature
Conclusion
INTRODUCTION

Casting : Metallic duplication of missing tooth structure.


Casting Technique : The process of obtaining a casting by pouring molten metal in to the mold after
dewaxing, which is allowed to solidify in the mold.

Defects in these castings are called Casting defects.

An unsuccessful casting results in considerable trouble and loss of time. These can be avoided by strict
observance of procedures governed by certain fundamental rules and principles. Seldom is a defect in a casting
is attributable to factors other than the carelessness or ignorance of the operator. With present techniques,
casting failures should be the exception, not the rule.
DEFENITIONS
1casting : something that has been cast in a mold; an object formed by the
solidification of a fluid that has been cast into a refractory mold

2casting : the action of pouring or injecting a flowable material into a refractory mold;
comp, VACUUM CASTING
Classification of defect in casting/common
causes of casting defects.
Classification

According to Anusavice
According to Anusavice
Distortion
Surface roughness and irregularities
Porosity
Incomplete or missing details
Based on location
Internal
external
According to Rosensteil
According to Rosensteil
Roughness
Nodules
Fins
Incompleteness
Voids or porosity
Marginal discrepancy
Dimensional inaccuracies
Fin
s Rough casting

Incomplete Large nodule


castings Multiple
suck back porosity

inadequate or
excessive
expansion.
According to O’Brien
General Problems with Problems
problems internal porosity external
with
porosity
accuracy localized shrinkage porosity back pressure
porosity
distortio subsurface porosity
n
micro porosity
bubbles
fins
short rounded
margins miscasting's
pits
Distortion

Causes:
 Can occur from the time of pattern preparation to the time of
investing due to stress relaxation.
 Distortion of the wax pattern occurs during the investment
procedure.

Minimized by:

 Application of minimum pressure


 Manipulation of wax at high temperature
 Investing pattern immediately
 If storage is necessary, store in refrigerator
Unquestionably some distortion of the wax pattern
occurs as the investment hardens around
it
Distortion can occur during spruing the
pattern because of the heat transferred to
the pattern
Pattern should be removed carefully from the die,
and should be invested
immediately.
Surface roughness
Surface Roughness and Irregularities

Surface roughness
Defined as relatively finely spaced surface imperfections whose
height, width and direction establish the predominant surface
pattern.

Surface irregularities
Isolated imperfections such as nodules that are not characteristic of
the entire surface area
REASONS FOR SURFACE ROUGHNESS
• Improper finishing of wax pattern
• Improper water powder ratio
• Excess surfactant
• Direct wax pattern
• Raid heating rates
• Underheating
• Too high pressure during casting
• Composition of investment
• Carbon inclusions
• Impact of molten alloy
• Pattern position
LIQUID/POWDER RATIO
The amount of water and investment should be measured
accurately.

 The higher the L/P ratio, the rougher the casting.

 Too little water  Investment thick and cannot be properly


applied to the pattern.

In vacuum investing, the air may not be sufficiently removed.

TO AVOID
Use the correct W/P ratio according to manufacturer’s
instructions
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 into the mold

 A surge of steam or water may carry certain salts into the mold that are left
behind in the walls as the water evaporates

TO AVOID

The mold should be heated gradually;atleastb60 min should elapse during the
heating of the investment filled ring from room temperature to 700 deg cel.
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 virtually


impossible to remove by pickling
CASTING PRESSURE

 Too high a pressure during casting can produce a rough surface on the casting

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 machine is


sufficient for small castings.
COMPOSITION OF THE INVESTMENT

 The ratio of the binder to the quartz influences the surface texture of the casting.

 A coarse silica causes a surface roughness.

 If the investment meets ANSI/ADA specification n0.2, the composition is


not a factor for surface roughness
IMPACT OF MOLTEN ALLOY

 Direction of sprue former molten gold alloy does not strike a weak portion
of the mold surface.

 Molten alloy may fracture or abrade the mold surface on impact, regardless of its
bulk.

TO AVOID
Proper Spruing To prevent the impact of molten metal at an angle of 90 degrees to
investment surface.
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


Causing breakdown or cracking 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


CARBON INCLUSIONS

Carbon, as from a crucible, an improperly adjusted torch, or a carbon-


containing investment, can be absorbed by the alloy during casting.

May lead to the formation of carbides or even create visible carbon inclusions
Control of surface roughness
Wetting agent be applied
in thin layer
Before starting to invest a direct wax pattern taken from
the mouth it should be washed in
water
Mold should be heated gradually, at least 60
min should elapse during the heating of the
investment filled ring from room temperature
to 700ºC.

A gauge pressure of 0.10 to 0.14 MPa in air pressure casting machine or 3 to 4 turns of
the spring in an average type of centrifugal casting machine is sufficient for small
casting.
Surface irregularities
Air bubbles:
 Small nodules on the casting

Prevented By:
 Proper investment technique
 Vibration of mix or by vacuum mixing
 Application of wetting agent properly and correctly – important that it be
applied in a thin layer.
Water films:
•If the Investment becomes separated from the wax pattern, a water
film may form irregularly over the surface.
•Appears as minute ridges or veins on the surface.
Prevented By:
1.Use of wetting agent
2.Correct L/P ratio (Too high L/P ratio may produce these
irregularities)
Rapid Heating Rates
Causes:
 Fins or spines
 Flaking of the investment
Prevented by:
 Heat gradually at least 60min from room temperature to 700°c.
 Greater the bulk – more slowly heated.

Under heating
 Incomplete elimination of wax residues.
Bubbles of gases trapped between the wax
pattern and the investment produce
nodules on the casting surface.
Large nodule- Air trapped during
investing
Multiple nodules – Inadequate vacum during mixing
Improper brush technique
Lack of surfactant.
Positive bubble –external part of the casting Positive bubble-margins and internal
portion of the casting

AIR ENTRAPMENT
Water Films
• Wax is repellent to water; if the investment becomes separated
from the wax pattern in some manner, a water film may form
irregularly over the surface.

• If the pattern is slightly moved, jarred, or vibrated after


investing or if the painting procedure does not result in intimate
contact of the investment with the pattern, such a condition
may result.
• If too little water is used, the investment may be un- manageably
thick, so that it cannot be properly applied to the pattern.
• A wetting agent is useful for the prevention of such
irregularities.
Prolonged heating
 Decomposition of the investment

Liquid/Powder Ratio
 The amount of water and powder measure should be accurate.

Casting pressure
 Too high pressure – rough surface of the casting
 Too low pressure – incomplete casting
 Average – 0.01 to 0.14 Mpa and 3 to 4 turns of the spring.
Foreign Bodies
• When foreign substances get into the mold a surface
roughness may be produced.

• A rough crucible former with investment clinging to


it may roughen the investment on its removal so
that bits of investment are carried into the mold
with the molten alloy.
 Any casting that shows sharp, well- defined deficiencies indicates the presence
of some foreign particles in the mold. They may be:
- Pieces of the investment
- Bits of the carbon from the flux
- Sulfur components from – decomposition of the gypsum investment and
high sulfur content torch flame.

Pattern position
 Should not place too close together
 Should not place many patterns in same plane

Space between the pattern is atleast 3mm


• Usually contamination results not only in surface roughness but also in incomplete
areas or surface voids.

• Any casting that shows sharp, well-defined deficiencies indicates the presence of
some foreign particles in the mold, such as pieces of investment and bits of carbon
from a flux.

• Bright-appearing concavities may be the result of flux being carried into the mould
with the metal.
Impact of metal alloy
Cause:
 The direct impact of molten alloy may fracture or abrade the mold surface
regardless of its bulk.
Prevented by:
 This type of surface roughness or irregularities can be avoided by proper spruing.

Carbon inclusions
 Carbon from- carbon crucible, carbon containing investment – absorbed by the
alloys during casting results in formation of carbides or visible carbon inclusion.
Surface irregularities on an experimental casting caused by air bubbles (A),water film (B),
and inclusion of foreign bodies(C).
Fin
 Prolonged heating- s Cracks in the investment
that radiate out from the
surface of the pattern.

 Heating rate is too rapid- Cracks may appear


in the investment, caused by nonuniform heating
of investment.

 Water/powder ratio- A high ratio produces


a weak investment that may crack.

 Excessive casting pressure- Metal impact may


cause investment fracture.

 Cooling of the investment prior to casting-


Cracks in the investment
TO AVOID FINS OR SPINES

Gradual heating of the mold- atleast 60 min should elapse during the heating of
the investment filled ring from room temperature to 700º C.

Greater the bulk of the investment, more slowly it should be heated.


Discolored castings

With calcium sulphate bonded


investments-color of the casting
in black after removal from the
investment
caus
e

wax not completely


eliminated
Mold remains in the oven
too long
Oxidizing flame was used
in melting the alloy
The investment did not contain deoxidizing
agent
s.
Other Causes
• Certain surface discolorations and roughness may not be evident when the
casting is completed but may appear during service. For example, various
gold alloys, such as solders, bits of wire, and mixtures of different
casting alloys should never be melted together and reused.Discoloration
and corrosion may also occur.

• A source of discoloration often overlooked is the surface contamination of a


gold alloy restoration by mercury. Mercury penetrates rapidly into the alloy
and causes a marked loss in ductility and a greater susceptibility to
corrosion.
• Thus it is not a good practice to place a new amalgam restoration
adjacent to a high noble alloy restoration. In addition, these dissimilar
metals form a galvanic cell that can lead to breakdown of the anode
(amalgam) relative to the cathode (noble alloy).
Porosities
Porosities in noble metal alloy castings may be
classified as follows:

I. Solidification defects
• A. Localized shrinkage porosity
• B. Microporosity

II. Trapped gases


• A. Pinhole porosity
• H. Gas inclusions
• C. Subsurface porosity

III. Residual Porosity


Localized shrinkage porosity

o caused by premature termination of the


flow of the molten metal during
solidification
o Linear contraction of noble metal
alloys in changing from a liquid to
solid is at least 1.25%.
o Therefore continual feeding of molten
metal through the sprue must occur to
make up for the shrinkage of metal
volume during solidification
If the sprue freezes in its cross-section before this feeding is
completed to the casting proper, a localized shrinkage void will occur
in the last portion of the casting that solidifies.

Localized shrinkage porosity in pontic of 3 unit


bridge caused by delayed solidification and lack
of a chill set sprue.
Remedy
• This problem can be solved by attaching one or more small-gauge
sprues

• These small chill set sprues ensure that solidification begins within the
sprues, and they act as cooling pins to carry heat away from the
pontic.
Microporosity

• Microporosity occurs from solidification shrinkage.

• It occurs when the solidification is too rapid for the micro-


voids to segregate to the liquid pool.

• This premature solidification causes the formation


of small, irregular voids.

• Such phenomena can occur from rapid solidification if the


mold or casting temperature is too low.
Pinhole- Porosity

• Oxygen is dissolved by some of the metals,


while they are in the molten state.

• During solidification, the dissolved gas is


expelled to form blebs and pores in the metal.

• The porosity that extends to the surface is


usually in the form of small pinpoint holes.

• When the surface is polished, other pinholes


appear.
Gas Inclusion Porosity
• The gas inclusion porosities are usually much
larger than pinhole porosity.

• Larger spherical porosities can be caused by


gas occluded from a poorly adjusted torch
flame or by use of the mixing or oxidizing
zones of the flame rather than the reducing
zone.

• If the alloy has been used before, these types


of porosities can be minimized by pre-melting
and correctly adjusting and positioning the
torch flame during melting.
Suck back porosity

• Improper sprue design causes suck back


porosity.
• The entering metal impinges onto the mold
surface and creates a higher localized mold
temperature in this region known as Hot spot.
• Hot spot may retain a localized pool of molten
metal after other area have solidified causing
shrinkage void or suck back porosity.
• This hot spot causes the local region to freeze last and results in
what is called suck-back porosity.

• Suck-back porosity often occurs at an occluso-axial line angle or


inciso-axial line angle that is not well rounded.

• This type of porosity defect can be eliminated by flaring the point of sprue attachment and
reducing the mold-melt temperature differential—that is, lowering the casting temperature by
about 30 °C.
Subsurface porosity

cause
d

Simultaneous nucleation of solid grains


and gas bubbles at the first movement
that the alloy freezes at the mold walls.

Can be diminished by controlling the rate at which the molten metal enters the
mold.
Back pressure porosity

• occurs on the inner surface of


the casting,
• produce large concave
depressions .
• This is caused by the inability of the air in the mold to escape through the pores in the
investment or by the pressure gradient that displaces the air pocket toward the end of the
investment via the molten sprue and button.

• Frequently found at the cavity surface of a


crown or mesio- occlusal-distal casting.
• It can be prevented by use of the dense
modern investments, by an increase in mold
density produced by vacuum investing, and
by the tendency for the mold to clog with
residual carbon when the low-heat technique
is used.
Since back pressure porosity occurs more generally in full crown type
castings, insertion of a wax rod into the core of the investment when
investing the pattern will provide a good means of venting the hot
gases quickly
Use of reservoir
The instance from the top of
the pattern to the outside of
the investment is kept to ¼
inch.
Furnace temperatures above 1100ºF
help eliminate this back pressure
porosity condition
Increasing the number of turns on a centrifugal machine and
increasing the casting pressure.
Performing the casting operation in
a
vacuum.
Using more metal when casting so that a good
size button is left is an important
precaution.
Hygroscopic low burn out technique produces more
of this porosity than high heat
techniques.
Thankyou 
REVIEW OF
LITERATURE
Lombardas P, Carbunaru A, McAlarney ME, Toothaker RW, of Dental S, Oral
Surgery NY. Dimensional accuracy of castings produced with ringless and metal
ring investment systems. The Journal of prosthetic dentistry. 2010 Jul
1;84(1):27 31.
• Lombardas et al did a study to determine “Dimensional accuracy of castings
producedwith ringless and metal ring investment systems”
• This study compared the vertical margin accuracy of lost wax castings produced with
the conventional casting technique using a metal ring and a technique that uses a ringless
system.
• From copings fabricated on a metal die,
1. 30 castings were produced from a high palladium alloy for metal ceramic restorations
2. 10 castings were cast with phosphate-bonded investment with the ringless technique
3. 10 were cast with the phosphate-bonded investment with a metal ring, and
4. The final 10 were cast using Hi-temp (Whip Mix) phosphate-bonded investment with a
metal ring.
• The internal surface of the castings were not modified before seating with finger pressure.
For vertical margin discrepancy measurements, an optical microscope at a magnification
of 100× was used. Data were analyzed with 1-way ANOVA (repeated measures) and the
Student test.

• When following the manufacturers’ recommendations, the castings of the ringless


technique provided less vertical margin discrepancy (mean value 181 ± 71 μm) than the
castings produced with the conventional metal ring technique (290 ± 87 μm and 291 ± 88
μm). The difference was significant (P<.001)
PrabhuKG, EswaranMA,PhanikrishnaG,Deepthi B.Sprue design
alterations and its effect on the properties of base metal alloy castings: An in vitro
study. Journal of pharmacy & bioallied sciences. 2015 Aug;7(Suppl 2):S524.

• Prabhu et al did a study on to evaluate “Sprue design alterations and its effect on the
properties of base metal alloy castings: An in vitro study.”
• To study the effect of various sprue designs on the properties of base metal alloy castings.
The base metal alloys are extensively used for their excellent properties such as an increase
in hardness, high melting range, high elastic modulus, its compatibility with ceramic
material and low cost.
• However, to improve the properties of the base metal alloys is leading to various
modifications in their fabrication procedure – which include sprue designs and their mode
of attachment to the wax pattern.
• Study compared the effect of three sprue designs on the properties of mass and micro-hardness
of base metal alloy castings. viz.
1. Conical sprue,
2. Cylindrical sprue and
3. Bottleneck sprue
• A prefabricated wax mesh pattern was selected for the fabrication of the alloy test samples in
the
study.
• The cylindrical sprue design was connected to the mesh pattern with a straight attachment.
• The bottleneck sprue design was connected to the mesh pattern with a constricted attachment.
• The conical sprue design was connected to the mesh pattern with a flared attachment.
• In this manner, ten samples for each of the three different sprue designs were prepared.
• Results:
The obtained value for mass and microhardness were subjected to statistical analysis.
ANOVA test was performed to determine the difference between the sprue designs.

• Conclusion:
The bottleneck sprue, conical sprue, and cylindrical sprue designs did not exert any apparent
influence on the mass and microhardness.
Earnshaw R. The effect of casting ring liners on the potential expansion of a
gypsum-bonded investment. Journal of dental research. 2010
Nov;67(11):1366- 70.
• Earnshaw R. did a study to determine “The effect of casting ring liners on the potential
expansion of a gypsum-bonded investment”
• A study was conducted on cellulose paper, ceramic paper and asbestos paper of the effects
on the setting and subsequent thermal expansion of a gypsum-bonded cristobalite casting
investment.
• Thermal expansion measurements were made on the same specimens that were produced
during the setting expansion tests.
• Control specimens setting against a smooth dry surface showed a total expansion of 1. 7%.
Specimens setting against dry ceramic liners had similar total expansions, in the range 1. 6
to 1. 7%.
• Specimens setting against either of the wet lining materials showed an increased total
expansion (in the range 2.2 to 2.3%), by virtue mainly of a large increase in setting
expansion.
• Dry asbestos and dry cellulose liners gave higher expansions than pre-wetted ones, since
they abstracted water from the mix, reducing its effective W/P ratio (giving a thicker mix),
and then functioned as wet liners.

• These results suggest that, at least as far as potential investment expansion is concerned, wet
cellulose liners have an effect similar to that of the traditional wet asbestos liners.

• Dry ceramic liners give a much lower investment expansion, and when these liners are used,
an investment with an increased measured expansion could be an advantage.
Baskaran BE, Prabhu KG, Prabhu R, Krishna GP, Eswaran MA, Gajapathi B.
Casting made simple using modified sprue design: An in vitro study. Indian
Journal of Dental Research. 2014 May 1;25(3):340.

• Baskaran et al did a study on “Casting made simple using modified sprue design: An in vitro
study”.
• Regardless of the alloy used for casting, the casting technique should yield a casted alloy,
whichshould possess sufficient mass, surface hardness and minimal porosity after casting.
• Twenty patterns for casting were made from three-dimensional printed resin pattern
simulating a 3 unit FPD and casted using modified sprue technique.
• Later test samples were cemented sequentially on stainless steel model using pressure
indicating paste and evaluated for vertical marginal gap in eight predetermined reference
areas.
• Marginal gap were measured in microns using Video Measuring System. A portion of the
axial wall of the cast abutments depicting premolar and molar were sectioned and embedded
in acrylic resin and tested for micro hardness and porosity.

• The results obtained for marginal gap, micro hardness, and porosity of all test samples were
tabulated, descriptive statistics were calculated and the values were found to be within the
clinically acceptable range.

• Thus new sprue technique can be an alternative and convenient method for casting which
would minimize metal wasting and less time consuming.
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.
REFERENCES
Operative Dentistry Modern theory and practice-
Marzouk

Dental materials – Philiphs –

Anusavice Full mouth rehabilitation –

Kornfield Restorative Dental materials

– Craig
Fixed prosthodontics – Rosenstiel
The Journal of prosthetic dentistry. 2010 Jul 1;84(1):27 31.

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