Escolar Documentos
Profissional Documentos
Cultura Documentos
Outline of Presentation
Spruing Technique High Heat Casting Investments Investing Technique Melting & Casting Technique Law Of Casting Analyzing Casting Failures
The Sprue
Definition: Its a channel through which molten alloy can reach the mold in an invested ring after the wax has been eliminated. Role of a Sprue: 1. Create a channel to allow the molten wax to escape from the mold. 2. Enable the molten alloy to flow into the mold which was previously occupied by the wax pattern.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
Sprue Former
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
Sprue Materials
Wax
Large restorations e.g. Removable partial denture frame works
Metal
Plastic
Smaller restorations
Significance
1. To avoid distorting thin areas of wax during attachment to the pattern. 2. To permit smooth flow of the alloy.
Maximum impedance to flow occurs when a Sprue former makes an angle of 90-degree to the pattern
*Laboratory Procedures for Full and Partial Dentures by Derek Stanananought
Fundamentals of Spruing, Investing & Casting
Significance
Since the molten metal may abrade or fracture investment in this area and may result in a casting failure. The entering metal impinges the mold surface at this point (90-degree angle) and creates hot-spot, producing a localized lingering of molten metal after the casting has solidified. Creates shrinkage void, or suck-back porosity.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
Significance
Short Sprue Length: The gases cannot be adequately vented to permit the molten alloy to fill the ring completely leading to Back Pressure Porosity. Long Sprue Length: Fracture of investment, as mold will not withstand the impact force of the entering molten alloy.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
The Crucible, Sprue and the Mould should be considered as being a wedge shape: 1. correct 2. incorrect
*Laboratory Procedures for Full and Partial Dentures by Derek Stanananought
Fundamentals of Spruing, Investing & Casting
Significance
Failure to cater for this may result in a reduction in density of the casting by the presence of voids called Porosity
This permits the reservoir to remain molten for longer and enables it to furnish alloy to the pattern until they complete solidification process
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Reservoirs
Round ball reservoir & a bar reservoir also called connector
Fundamentals of Spruing, Investing & Casting
Significance
Reservoir is the largest mass of any part of the Sprue system & it is present in the heat centre of the ring, it is the last part to solidify. These properties allow continuous feeding of the molten alloy to compensate for Solidification shrinkage & avoid Shrinkage porosity.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
Spruing Techniques
1. Direct Spruing: The flow of the molten metal is straight(direct) from the casting crucible to pattern area in the ring. Even with the ball reservoir, the Spruing method is still direct. A basic weakness of direct Spruing is the potential for suck-back porosity at the junction of restoration and the Sprue.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Suck-back porosity
It can be seen at the junction of restoration and Sprue
2. Indirect Spruing: Molten alloy does not flow directly from the casting crucible into the pattern area, instead the alloy takes a circuitous (indirect) route. The connector (or runner) bar is often used to which the wax pattern Sprue formers area attached. Indirect Spruing offers advantages such as greater reliability & predictability in casting plus enhanced control of solidification shrinkage
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Noncarbon-containing
White color before and after mixing. Used with nickel- and cobalt-base casting alloys, as well as palladium-based noble metal alloys. Because these alloy systems are capable of dissolving available carbon to produce carbides and/or porosity (due to carbon inclusions)
Nodule formation and fins may occur more frequently with one brand of investment but not with other. Therefore, it is prudent to conduct laboratory tests for adverse alloy-investment interaction before making a large purchase of a new product (Naylor,1990).
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Rough casting with multiple nodules may be caused by a less-than-ideal alloy-investment pairing
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Asbestos fiber bundles were found to produce hazardous-size respirable particles capable of causing lung disease.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
2.
Non-asbestos Ring Liners: Ceramic (aluminum silicate) Cellulose (paper) Ceramic-cellulose combination Safety of the ceramic ring liners remains uncertain, because aluminum silicate also appears capable of producing hazardous-size respirable particles (Naylor
et al,1987).
Investing Technique
1. The wax pattern cleaned of any debris, grease or oil. Wax pattern cleaner or diluted synthetic detergent. Thin film of cleaner on pattern reduces surface tension of wax better wetting of investment.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
2. Investment mixing Hand mixing Vacuum mixing Advantages Amount of porosity in the investment is reduced Texture of the surface casting is smoother with better detail reproduction Compressive strength of investment is increased
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
3. Investment material pouring Casting ring is filled up to its rim. Allow the investment to set for about 1 hour. Crucible former is carefully removed. If burnout procedure does not immediately follow investing, place ring in humidor.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
4. Wax elimination & heating Invested ring is placed in a room temperature furnace. Phosphate-bonded investments---temperature range----700 to 870*C Temperature rate of rise for the burnout furnace is 10*C/min
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips *Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
It is advisable to begin the burnout procedure while the mould is still wet. Water trapped in the pores of the investment reduces the absorption of wax. As the water vaporizes it flushes wax from the mold.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Choice of Fuels
Three fuel sources are used for Casting Torch 1. Acetylene 2. Natural Gas 3. Propane
Zones of Flame
1. Zone in which air & gas are mixed before combustion: No heat is present in this zone. 2. Combustion zone: Green, gas & air are in partial combustion. This zone is oxidizing & should always be kept away from metal during fusion.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
3. Reducing zone: Dimly blue, hottest part of the flame. This area should be constantly on the metal during fusion. 4. Oxidizing zone: Outer most zone, here combustion occurs with Oxygen in air. Under no circumstances should this portion be employed to fuse the alloy. Low temperature, Causes oxidation of the metal.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
When the reducing zone is in contact, the surface of the gold alloy is bright and mirrorlike. When the Oxidizing zone is in contact the metal there is a dull film of dross developed over the surface.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Casting Machines
1. Air pressure casting machines Alloy is melted in situ in crucible hollow of the ring, followed by applied air pressure on the melt. 2. Centrifugal casting machine Alloy is melted in a crucible, and forced in to mold by centrifugal force. 3. Electrical Resistance/ Induction melting machine Alloy is melted electrically by a resistance or induction furnace, then cast into mold centrifugally.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
Base
Casting Crucible
Except for Air pressure casting machine, all other units require a crucible to hold the alloy before & during melting procedure. 1. Clay Crucibles 2. Carbon Crucibles 3. Quartz Crucibles (zircon-alumina)
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Quenching in Water
Consider the gold crown & bridge alloys. After casting has been completed, ring is removed & quenched in water. Advantages: 1. Noble metal is left in an annealed condition for burnishing & Polishing. 2. When water contacts hot investment, violent reaction ensues. Investment becomes soft, granular & casting is more easily cleaned.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing & Casting
Pickling
Surface of the casting appears dark with oxides and tarnish. Such a surface film can be removed by a process called Pickling. Best method for pickling is to place a casting in a dish & pour acid over it. Heat the acid but don't boil it.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Hydrochloric acid Sulfuric acid Ultrasonic devices Gold and palladium based metal ceramic alloys and base metals, these alloys are not generally pickled.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
The
st 1
Law of Casting
Attach the pattern Sprue former to the thickest part of the wax pattern
As the molten metal alloy moves from the reservoir to the pattern margins it should flow from areas of greater volume to areas of lesser volume (ie, margins). Lute the pattern Sprue former to the most practical portion of the occlusal/incisal surface. Molten metal flowing from thin area to a thicker region(full waxup) may solidify before the mold is completely filled.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
Penalties for not obeying this law are: Clod shuts Short margins Incomplete castings
The
nd 2
Law of Casting
Orient wax pattern so all the restoration margins will face the trailing edge when the ring is positioned in the casting machine
Fundamentals of Spruing, Investing & Casting
To identify that orientation, add a wax dot to the crucible former so you know how to place the ring in the casting cradle correctly after the pattern have been invested.
Penalties
Penalties for not obeying this law are: Cold shuts Short margins
The
rd 3
Law of Casting
Position the wax pattern in a cold zone of the investment mold and the reservoir in the heat centre of the casting ring
Fundamentals of Spruing, Investing & Casting
The coolest parts of the mold (cold zones) are the end of the ring and along the ring periphery. The hottest portion of the casting ring is located near the centre of the ring (heat centre). Limit the amount of investment covering the patterns to no more than inch (6mm) & position the reservoir in the heat centre. Adherence to this law increases the likelihood that casting porosity will occur in the reservoir rather than in the restoration.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalty for not obeying this law is: Shrink-age porosity
The
th 4
Law of Casting
A reservoir must have sufficient molten alloy to accommodate the shrinkage that occurs within the restorations
Fundamentals of Spruing, Investing & Casting
Alloy that fills the restoration will solidify first. As the molten metal solidifies, it shrinks and creates a vacuum. For a complete casting, the vacuum must be able to draw additional metal from an adjacent source--the reservoir. Reservoir should be equal to or greater than the thickest cross-section area of the wax pattern.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalty for not obeying this law are: Shrink-age porosity Suck-back porosity
The
th 5
Law of Casting
Do not cast a button if a connector (runner) bar, or other internal reservoir, is used
Fundamentals of Spruing, Investing & Casting
With indirect Spruing, the largest mass of metal should be the reservoir. A button is counterproductive because it can draw available molten alloy from the bar, shift the heat centre and reduce the feed of that metal to the restorations. Likewise, the wax pattern should not be larger than the connector bar shift the heat centre.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalties for not obeying this law are: Shrinkage porosity (and potential Distortion during porcelain firing) Suck-back porosity
The
th 6
Law of Casting
Pathways for the flow of metal should be smooth, gradual, and without impediments. Eliminate sharp turns, restrictions, points, or impingements that might create turbulence and occlude air in the casting. Restrictions, or constrictions, can accelerate the metal's rate of flow and abrade the mold surface (Ingersoll & Wandling,1986).
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalties for not obeying this law are: Voids in the casting ring Surface pitting
The
th 7
Law of Casting
Select a casting ring of sufficient length and diameter to accommodate the patterns to be invested
Fundamentals of Spruing, Investing & Casting
The casting ring should permit the patterns to be in. apart and in. from the top of the investment with a minimum 3/8 in. of investment between them and the ring liner. If too little investment covers the wax patterns, the alloy is more likely to break through he mold. Too much investment over the waxups may locate the wax patterns too close to the heat centre of the mold and impair the escape of gases.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalties for not obeying this law are: Mold fracture Casting fins Shrinkage porosity
The
th 8
Law of Casting
A wetting agent should be brushed or sprayed on the patterns and dried before investing. A clean wax surface better enables the casting investment to wet the patterns more completely. Too much wetting agent can create a surface film that can dilute and weaken the investment in that area and produce bubbles or fins on the casting.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Apply a thin layer of debubblizer (wax pattern cleaner) to the wax patterns and indirect Spruing system and allow it to dry thoroughly before investing
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalty for not obeying this law is: Bubbles On the surface of the casting as a result of the entrapment of air (too little agent) or excess liquid (too much wetting agent).
The
th 9
Law of Casting
Weigh any bulk investment and measure the investment liquid for a precise powder-liquid ratio
Fundamentals of Spruing, Investing & Casting
The correct proportion of powder to liquid and any dilution of the (special) liquid with distilled water should be established for each alloy. A thick mix of investment (reduced liquid) increases investment expansion & produces loose-fitting castings. Too much liquid results in thinner mix and less expansion with tighter-fitting castings. Using all special liquid provides more expansion but reduces working time compared to 50:50 dilution of the special liquid and distilled water.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalty for not obeying this law is: Ill-fitting castings
The
th 10
Casting Law
Eliminate the incorporation of air in the casting investment and remove the ammonia gas by product of phosphate-bonded investments by mixing under vacuum
Fundamentals of Spruing, Investing & Casting
Vacuum mixing removes more air and gas than hand spatulation. Ares of the mold that contain dense, bubblefree investment will expand differently from sections that contain large voids (entrapped air).
Penalties
The penalties for not obeying this law are: Small Nodules on the casting Weak mold Distortion of the casting
The
th 11
Law of Casting
Allow the casting investment to set completely before initiating the burnout procedure
Fundamentals of Spruing, Investing & Casting
If setting is not complete at the time a ring is placed in the oven, the mold may be weak and unable to withstand steam expansion during burnout. Investment could fracture as a consequence. For best results, burnout should be initiated only after the recommended setting time.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalties for not obeying this law are: Mold crackling/Blowout Fins on the casting
The
th 12
Law of Casting
Use a wax elimination (burnout) technique that is specific for the type patterns involved (wax versus plastic) and recommended for the particular type of casting alloy selected
Fundamentals of Spruing, Investing & Casting
Plastic Sprues need to be heated slowly so they can soften gradually and not exert pressure on the mold, so use a two-stage burnout (Tombasco & Reilly,1987). If burnout is incomplete, the spruing system channels may be blocked by wax or plastic residue (carbon) and, on casting, air cannot escape completely when metal enters the mold (Naylor,1990a;
Tombasco & Reilly,1987).
Therefore, use at least a 30-minute heat-soaking at 800 *F for the first burnout stage.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalties for not obeying this laws are: Cold Shuts Short Margins Cold Welds Mold Cracks Casting Fins
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
The
th 13
Law of Casting
Adequate heat must be available to properly melt and cast the alloy (Myers,1936)
Fundamentals of Spruing, Investing & Casting
The selected heat source should be capable of melting the alloy to the point of sufficient fluidity. Prolonged heating, caused by an improperly adjusted torch, can prevent the alloy from attaining the fluidity. Too much heat, or too high temperature, can burn off minor alloying elements.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalties for not obeying this law are: Cold Shuts Short Margins Cold Welds (too little heat) Rough Castings Investment Breakdown (too much heat)
The
th 14
Law of Casting
When torch casting, use the reducing zone of the flame to melt the alloy and not the oxidizing zone
Fundamentals of Spruing, Investing & Casting
An improper adjusted torch can add carbon or oxygen to the alloy while heating. A melt achieved by the exclusive use of the Reducing zone minimizes the likelihood of metal oxidation and gas absorption and ensures a proper melt.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalties for not obeying this law are: Gas porosity Change in the alloys Coefficient of thermal expansion (due to alloy contamination)
The
th 15
Law of Casting
Provide enough force to cause the liquid alloy to flow onto the heated mold
Fundamentals of Spruing, Investing & Casting
Adjust the casting machine to the requirements of each alloy. Lower-density metals generally need four winds of a centrifugal casting arm as compared to higher-density, gold based alloys. Don't over wind.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalties for not obeying this law are: Cold Shuts Short Margins Clod Welds (insufficient force) Mold Fracture & Fins (too much force)
The
th 16
Law of Casting
Place the heated ring in the casting cradle using the orientation dot so the pattern margins face the trailing edge (the 2nd law). In a centrifugal casting machine the metal will flow downward and to the right, taking advantage of the centrifugal, rotational, and gravitational forces of molten alloy (Ogura et
al,1981; Ingresoll & Wandling,1986).
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalties for not obeying this law are: Cold shuts Short margins Incomplete castings
The
th 17
Law of Casting
Allow the alloy and the investment to cool to room temperature. Uneven cooling and shrinkage between alloy and investment can apply tensile forces to the casting (Cascone,1976). After casting, the alloy may not possess sufficient strength to resist these forces and the restoration could tear, if quenched.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing & Casting
Penalties
The penalty for not obeying this law is: Hot Tears in the restoration
Thank You!