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CASTING DEFECTS

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Dr. Sriharsha Vadapalli 3/5/13

DEFINITION
Casting is the process by which an object is formed by the solidification of a liquid that has been poured or injected into a mold.

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Once the investment has set for an appropriate period of 1 hr for gypsum & phosphate bonded investment, it is ready for burn out

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History

1905-LOST WAX PROCESS 1933-Replacement of CO-Cr for gold in RPD 1950-Development of resin veneers for gold alloys

1959-Porcelain fused to metal technique 1971-The Gold standard 1980-ALL-CERAMIC TECHNOLOGIES


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LAWS OF CASTINGS -W.Patrick Naylor

LAW I :

attach the pattern sprue former to the thickest part of wax pattern.

Pitfalls : Cold shuts, short margins, incomplete castings

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LAW 2 :

orient wax pattern so all the restoration margins will face the trailing edge when the rim is positioned in the casting machine

Pitfalls : cold shuts, short margin

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LAW 3 :

position the wax pattern in a cold zone of investment mold and reservoir in the heat centre at the casting ring

Pitfalls : shrinkage porosity

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LAW 4 : a reservoir must have sufficient molten alloy to accommodate the shrinkage that occurs within the restoration Pitfalls : shrinkage porosity and suckback porosity

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LAW 5 :

do not cast a button if a connector (runner)bar or other internal reservoir is used

Pit falls : shrinkage porosity, distortion , suckback porosity

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LAW 6 :

turbulence must be minimised, if not eliminated

Pitfalls : voids & surface pitting

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LAW 7 :

select a casting ring of sufficient length and diameter to accommodate the pattern to be invested

Pitfalls : mould fracture, casting fins, shrinkage porosity

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LAW 8 :

increase the wettability of wax pattern.

Pit falls : bubbles.

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LAW 9 :

weigh any bulk investment and measure the investment liquid for a precise liquid : powder ratio

Pitfalls : ill fitting castings

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LAW 10 :

eliminate the incorporation of air in the casting investment and remove the ammonia gas, the byproduct of phosphate bonded investments under vaccum.

Pitfalls : small nodules, weak mould,distortion

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LAW 11 :

allow the casting investment to set completely before initiating the burn out procedure.

Pitfalls : mould cracking or blow out , fins

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LAW 12 :

use a wax eliminator (burn out) technique that is specific for the type of pattern involved (wax/ plastic) and recommended for the particular type of casting alloy selected

Pitfalls : cold shunts, short margins, cold welds, mold cracks , fins

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LAW 13 :

adequate heat must be available to properly melt and cast the alloy ( myers 1936)

Pitfalls : cold shuts, cold margins, cold welds, rough castings,, investment breakdown

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LAW 14 : while torch casting,use the reducing zone of flame to melt the alloy and not the oxidising zone. Pitfalls : gas porosity , change in the coefficient of thermal expansion of alloy.

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LAW 15 :

provide enough force to cause the liquid alloy to flow into the heated mould.

Pitfalls : cold shuts, short margins, cold weld, mould fracture, fins

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LAW 16 :

cast turned towards the margin of wax pattern .

Pitfalls : cold shuts, short margins, incomplete castings

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LAW 17 :

do not quench the ring immediately after casting.

Pit falls : hot tears in the restoration.

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DEFECTS IN CASTINGS

DISTORTION SURFACE ROUGHNESS/ IRREGULARITIES POROSITY INCOMPLETE / MISSING DETAIL


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DISTORTION

CAUSES :

By distortion of wax pattern by carelessness of operator and by hardening of investment around the pattern .Also by uneven outward movement of proximal walls. The configuration of pattern,wax type and wax thickness influence the distortion
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EFFECTS :

Not a serious problem except for the unexplained inaccuracies in small castings.

PREVENTION :

By proper manipulation of wax and handling of pattern.There is probably not a great deal that can be done to control this phenomenon.
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SURFACE ROUGHNESS, IRREGULARITIES, DISCOLORATION

DEFINITION :

Surface roughness is defined as finely spaced surface imperfections whose height, width,and direction establish the predominant surface pattern
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Surface irregularities refer to isolated imperfections such as nodules that do not characterise the total surface area. Excessive roughness or irregularities on outer surface of casting necessitates additional finishing and polishing whereas irregularities on the cavity surface prevent a proper seating of an otherwise accurate casting.
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The greater surface roughness of casting compared to its wax pattern is related to the particle size of investment and its ability to reproduce wax pattern in microscopic detail This is not a major problem with proper manipulative technique.
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Air bubbles

Cause :

Air bubbles form during or subsequent to the investing procedure .They form nodules .

Effect : Affect the fit of casting. Prevention :

Use Vacuum investing 3/5/13 technique

For Manual Method : Use mechanical mixer with Vibrations before and after mixing. Use of Wetting Agent prevent air bubbles on the surface of the pattern. Nodules not in critical areas can be removed. Those in critical areas affect the fit of casting.

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Water films

Cause :

By seperation of investment from wax pattern by slight movement of pattern. Also results when painting / wetting agent does not result in an intimate contact of investment with the pattern.
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Effect of High L : P Ratio

Effect :

Minute ridges or veins on the surface of castings.

Prevention : Use of wetting agents.

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RAPID HEATING RATES


EFFECTS :

Fins / Spines on castings. It is the characteristic surface roughness seen on rapidly heating the mould and high temp. of the molten alloy. Steam carry some salts used as modifiers into mould which are left as deposits on walls after the 3/5/13 water evaporates.

PREVENTION : Gradual Heating of the

Mould over a time period of 60 min.

Greater the Investment bulk , slower should be the rate of heating.


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UNDER HEATING
EFFECT :

Voids / porosities formed when the hot alloy comes in contact with carbonaceous residues . Tenacious carbon coating on casting is resistant to pickling. Common with low temp. investment technique.
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LIQUID : POWDER RATIO

EFFECT : Rougher casting by

improper L: P Ratio.

PREVENTION :

Gauge the Amount of Water and Investment accurately.


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PROLONGED HEATING
EFFECTS : Common with High Heat Casting Technique. Roughened Walls of mould by disintegration of investment. Surface texture affected by sulfur compounds which are the products of decomposition of the investment.( does not respond to 3/5/13 pickling)

PREVENTION :

When the Thermal Expansion Technique is employed mould should be heated to casting temp. never higher than 700 deg.celsius and casting should be made immediately.

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TEMPERATURE OF ALLOY

CAUSES : Over Heating of Alloy. EFFECTS :

Surface roughness by disintegration of investment surface.

PREVENTION :

No Over Heating of alloy with Gas Air torch.


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CASTING PRESSURE

EFFECT :

Rough casting by raised pressure.

PREVENTION :

With Air Pressure casting machine ( 0.10 0.14 Mpa gauge pressure)
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Average centrifugal casting

COMPOSITION OF INVESTMENT
EFFECTS : Surface Roughness by coarse silica Surface texture affected by binder quartz PREVENTION : Follow ADA SP NO .2 for investments. 3/5/13

FOREIGN BODIES
CAUSES :

Rough Crucible former with investment clinging to it. Carelessness in the removal of sprue former. Contamination from sulfur

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EFFECTS :

Contamination result in surface roughness , incomplete areas or voids. Foreign particles involved produce sharp, well defined deficiencies. Bright appearing concavities by flux carried to the mold Surface Roughness Sulfur 3/5/13 contamination Black castings

IMPACT OF MOLTEN ALLOY

CAUSES : Mis direction of Sprue

former.

EFFECTS :

Raised areas on casting that prevents its seating.

PREVENTION :

PROPER SPRUING to prevent Direct Impact of molten metal at an angle of 90 degree to investment surface. 3/5/13

PATTERN POSITION

CAUSES :

CLOSE PACKING - pattern positioning in the same plane.

EFFECTS : Breakdown / Cracking of

investment.

PREVENTION :

Keep 3 mm between patterns & place the pattern in different planes. 3/5/13

CARBON INCLUSIONS

CAUSE:

Carbon absorbed by alloy during casting from an improperly adjusted torch or carbon containing investment

EFFECTS :

Visible carbon inclusion and carbides


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Wax Elimination & Heating

For gypsum bonded investment

500C for hygroscopic technique. 700C for thermal expansion technique. 700C to 1030C.

Phosphate bonded

Advisable to begin burn-out procedure when the mould is still wet.

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Hygroscopic Low Heat Technique

Obtains compensation expansion from 3 sources.


37C water bath expands wax pattern. Warm water entering the investment mold from top adds some hygroscopic expansion. Thermal expansion at 500C provides needed thermal expansion.

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Advantages of Low Heat Technique

Less investment degradation. Cooler surface for smoother castings. Convenience of placing molds directly in 500C furnace.

Care taken for sufficient burnout time. The molds should remain in furnace for atleast 60 min.

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Back pressure porosity great hazard in low

Standardized hygroscopic technique was developed for alloys with high gold content; the newer noble alloy may require slightly more expansion. This added expansion may be obtained by making 1 or more of following changes.
1.

Increasing water bath temperature to 40C. Using two layers of liners. Increasing burnout temperature to a range of 600C to 650C.

2. 3.

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High-Heat Expansion Technique

Depend almost entirely on high-heat burnout to obtain the required expansion, while at the same time eliminating the wax pattern. Additional expansion:

Slight heating of gypsum investments on setting. Thus expanding the wax pattern. Water entering from wet liner adds a small amount of hygroscopic expansion to the normal setting expansion.

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Gypsum Investments

Fragile and require use of metal ring. Slowly heated to 600C to 700C in 60 mins. and held for 15 to 30 min. at the upper temperature. Rate of heating: Smoothness. Overall dimension of investment. Too rapid heating.
Cracking of investment outside layer expands more than center section. Radial cracks interior to outward. Casting with fins or spines.

Investment decomposition and alloy contamination is related to the chemical reaction between the residual carbon and sulfate binder. Calcium sulfate does not decompose unless heated above 1000C. Reduction of calcium sulfate by carbon takes place rapidly above 700C.

CaSO4 + 4C CaS + 4CO 3CaSO4 + CaS 4CaO + 4SO2

This reaction occurs when gypsum investment are heated above 700C in presence of carbon. SO2 as a product of this reaction contaminates gold castings and makes them extremely brittle.
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Sulfur gases are generated when investment is heated above 700C.

After casting temperature reached Casting should be made immediately.

Sulfur contamination. Rough surface on casting.

Improved investment formulations.

Gypsum investment with considerable amount of cristobalite.

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Few investments may be directly held for 30 min. & placed into cast. furnace at final burnout Factors affecting size and smoothness. temperature Design of the furnace. Proximity of the mold to the heating element. Availability of air in the muffle.

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Phosphate Investments

Obtain their expansion from following sources.


Expansion of the wax pattern. Setting expansion (because of liquid used). Thermal expansion

Phosphate investments much harder and stronger than gypsum investments. Burnout temperature range from 750C to 1030C. 315C rapid heating held at the upper temperatures for 30 mins. 3/5/13

2 stage heating:

Placed directly in furnace at top temperature. Held for 20-30 min. then cast

Elimination of metal ring and liner to save more time.

Metal ring replaced with plastic ring i.e. tapered.

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Time allowable for casting

Investment contracts thermally as it cools. When thermal expansion / high heat technique used. Investment loses heat after heated ring removed from furnace and mold contracts.

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Low heat technique


Temperature gradient not great. Thermal expansion not important to shrinkage compensation.

High heat technique


Great temperature gradient. Thermal expansion important.

Burnout temperature on a Burnout temperature on fairly steep portion of thermal thermal expansion plateau. expansion curve.

Casting Machines
Alloys are melted in one of the 4 following ways: In a separate crucible by a torch flame, and cast centrifugally. Electrically by a resistance heating or induction furnace. Centrifugally by motor or spring action. By induction heating. Centrifugally by motor or spring action. Vacuum arc melted. Cast by pressure in argon atmosphere. Molten metal may be cast by air 3/5/13 pressure, by vacuum, or both.

Torch Melting of Noble Alloy


Melted by placing on inner sidewall of crucible. Fuel used - Natural or artificial gas and air. - Oxygen air and acetylene. Non-luminous brush flame with different combustion zones should be obtained. Mixing zone Combustion zone. Reducing zone. Oxidizing zone. At proper casting temperature the molten alloy is light orange and tend to spin or follow the flame. 3/5/13

The casting should be made when proper temperature is reached

No more 30 secs should be allowed to elapse between the time the ring is removed from the oven and the molten alloy is centrifuged into the the mold

When the alloy is molten,slide the crucible against the ring,sprinkle flux over the metal

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Hold the casting arm so that the pin drops

Use of flux for gold alloy

It is desirable to use flux for gold alloy to minimize porosity. To increase the fluidity of the metal film of flux formed on surface of alloy prevents oxidation

Reducing fluxes: Reduce oxides the present to free metal and oxygen. Excellent in cleaning old alloy.

E.g. 1.Powdered charcoal 2.Fused Borax powder ground with Boric

CENTRIFUGAL CASTING MACHINE

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Torch melting centrifugal casting machine


Casting machine spring wound from 2 to 5 turns Alloy is melted by a torch flame in a glazed ceramic crucible attached to the broken-arm of casting machine. Torch flame is generated from a gas mixture of propane and air. Machine is released and spring triggers the rotation motion. As the metal fills the mold, a hydrostatic pressure gradient develops along the length of the casting.

Broken arm feature accelerates the initial rotational speed of the crucible and casting ring.

The pressure gradient from the tip of the casting to the bottom surface is quite, sharp and parabolic in form, reaching zero at the button surface. Pressure gradient before solidification reaches 0.21 to 0.28MPa (30 to 40 psi) at the tip of casting. Greatest rate of heat transfer to the mold is at the high pressure end of the gradient (tip of the casting).
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SPRING-WOUND CASTING MACHINE WITH ELECTRIC RESISTANCE FURNACE

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Current is passed through a resistance heating conductor, and automatic melting of the alloy occurs in a graphite or ceramic crucible. Advantages: For metal ceramic prosthesis. Base metals in trace amounts that tend to oxidize on overheating. Crucible located flush against casting ring. Carbon crucibles should not be used in melting of: High Pd 3/5/13

Electrical Resistance-Heated Casting Machine

INDUCTION MELTING CASTING MACHINES

WATER COOLED INDUCTON COIL

VERTICAL CRUCIBLE POSITOINED WITHIN INDUCTION COIL

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Induction Melting Machine

Alloy is melted by induction field that develops within a crucible surrounded by water cooled metal tubing.

The electrical induction furnace is a transformer in which an alternating current flows through the primary winding coil and generates a variable magnetic field in the location of the alloy to be melted in crucible.

Once the alloy reaches casting temperature in air/vacuum it is forced into mold by centrifugal
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by air pressure, or by vacuum.

Direct Current Arc Melting Machine

Direct current arc is produced between two electrodes- the alloy and water cooled tungsten electrode. The temperature between the arc exceeds 4000C. Has high risk of overheating.

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Vacuum or Pressure Assisted Casting Machine

Molten alloy is heated to casting temperature drawn into the evacuated mold by gravity or vacuum and subjected to additional pressure to force the alloy into the mold. Used for titanium and titanium alloys. Under vacuum arc heatedargon pressure casting machine.
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Casting Crucibles

Clay. Carbon. Quartz. Zirconia-alumina.

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Cleaning the casting

Quenching: ring is removed and quenched in water as soon as the button exhibits a dull red glow Purpose of quenching

All the intermediate phases are changed to a disorderly state and ductility is increased Soft granular investment that is easily removed

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Devesting or Sand blasting

Casting is held in an sand blasting machine to clean the investment from the surface. The blasting materials used are:

Sand shells Recycled aluminium oxide with pressure of 100psi Garnet

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Pickling
Removal of oxide residues of carbon by heating the discoloured casting in an acid Advantages of HCl: v Aids in removal of residual investment as well as oxide coating Disadvantages: v Likely to corrode laboratory metal furnishings v Fumes are health hazard
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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 solution Finishing and polishing : Brown or White AlO2 stones are used Cleaning : Using a hemostat, steam or clean framework
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CASTING DEFECTS

Casting is defined as the act of forming an object in a mold. The object formed from this procedure is called a casting. Any impressions or irregularities that result in unsuccessful casting which interfere with the fit of the final restoration-basically classified into 4 categories DISTORTION SURFACE ROUGHNESS AND 3/5/13 IRREGULARITIES

POROSITY
Defined as the state of quality of having minute pores,openings or interstices. EXTERNAL POROSITY : It can be a factor in surface roughness or manifestation of internal porosity. INTERNAL POROSITY : It can weaken the casting and it extends to surface, lead to discoloration.In severe cases, it causes 3/5/13 leakage at tooth restoration interface

TYPES OF POROSITIES
SOLIDIFICATION DEFECTS : A) localised shrinkage porosity B) Microporosity TRAPPED GASES : A)Pin hole porosity B)Gas inclusions C)Sub surface porosity RESIDUAL AIR

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SURFACE IRREGULARITIES
Air bubbles Water films Rapid heating under heating and prolonged heating Liquid/powder ratio Temperature of alloy Casting pressure Composition of investment Foreign bodies Impact of molten alloy 3/5/13 Pattern position

SURFACE IRREGULARITIES
A)AIR BUBBLES B)WATER FILMS C)FOREIGN BODY
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BLACK COATED NOBLE METAL ALLOY

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POROSITY
SOLIDIFICATION DEFECTS LOCALISED SHRINKAGE POROSITY MICROPOROSITY TRAPPED GASES PINHOLE POROSITY GASINCLUSIONS SUBSURFACE POROSITY 3/5/13 RESIDUAL AIR

LOCALISED SHRINKAGE POROSITY

Premature termination of flow of molten metal Sprue freezes before feeding complete to casting proper Retain heat because of bulk and heat center of ring Small chill set sprues

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CAUSES : Incomplete feeding of molten metal during solidification. commonly it occurs near to sprue casting junction or in the interior of crown near the sprue EFFECTS : A Localised shrinkage void in the last portion of casting that solidifies PREVENTION : 3/5/13 Attach one or more

LOCALISED SHRINKAGE POROSITY

MICROPOROSITY

Occurs by solidification shrinkage in fine grain castings Occur from rapid solidification if mold /casting temperature is too low

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MICROPOROSITY

Seen in fine grain Alloy castings when solidification is too rapid for the microvoids to segregate to liquid pool. It can occur when mould or casting temp. is too low. EFFECTS :

Small irregular voids, not a serious defect.


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SUCK BACK POROSITY

Occlusoaxial/incis oaxial line angle Hotspot Flaring the point of sprue attachment Lowering casting temperature by 30 degrees

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SUCKBACK POROSITY
A Type of Localised Shrinkage Porosity occuring in the interior of a crown near the area of sprue.It forms when a Hot Spot has been created by the hot metal impinging from the sprue channel on a point of mould wall. It causes the local region to freeze last. Can be eliminated by Y sprue instead of single sprue , flaring the point of sprue attachment and by 3/5/13

PINHOLE POROSITY AND GAS INCLUSIONS

Entrapment of air during solidification Spherical contour large spherical porosities caused by gas occluded by a poorly adjusted torch flame

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SUB SURFACE POROSITY

CAUSES :

Not completely established.Caused by simultaneous nucleation of solid grains and gas bubbles at the first moment that the metal freezes at the mould walls.

PREVENTION :

Control the rate at which the molten metal enters the mould.
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SUB SURFACE POROSITY

simultaneous nucleation of solid grains and gas bubbles at the first moment that the alloy freezes at the mold walls rate of molten metal that enters the mold

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BACK PRESSURE POROSITY

Large concave depressions Inability of air in mold to escape through the pores in the investment Proper burnout,adequate mold and casting temperature,high

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INCOMPLETE CASTING

MOLTEN ALLOY PREVENTED FROM COMPLETELY FILLING MOLD Insufficient venting and high viscosity Incomplete elimination of wax residues Shiny margins caused by CO left by residual wax Temperature of alloy should be raised so that its viscosity and surface tension are lowered.
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INCOMPLETE CASTINGS
CAUSES :

Insufficient venting of mould high viscosity of fused metal Insufficient venting is related to the backpressure exerted by air in mould and incomplete elimination of wax residues from mould. Apply appropriate casting pressure for 3/5/13 4 sec .

PREVENTION :

Raise the Alloy Temperature greater than its Liquidus temperature so that its viscosity and surface tension are lowered and it does not solidify prematurely as it enters the mould.

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INCOMPLETE CASTING

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ROUNDED INCOMPLETE MARGNS

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RESIDUAL AIR

ENTRAPPED AIR POROSITY / BACK PRESSURE POROSITY : CAUSES :

Inability of air in the mould to escape through the pores in investment or by pressure gradient that displaces the air pocket towards the end of investment via molten sprue and button.
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Its incidence is increased by dense modern investments , increase in mould density caused by Vacuum investing and tendency for mould to clog with residual carbon when low heat technique is used . EFFECTS : Large concave Depressions PREVENTION : Proper burn out , adequate mould & casting temp. , sufficiently 3/5/13 high casting pressure, proper l: p ratio.

TRAPPED GASES
PINHOLE - GAS INCLUSION POROSITY: Both are similar except for their size, gas inclusion porosities are LARGER. CAUSES : Due to Gas Entrapment during Solidification. Copper & Silver can dissolve oxygen while pt & pd have a strong affinity for H2. 3/5/13

EFFECTS :

In the form of voids or Discoloration

PREVENTION :

Premelting Gold Alloy on a Graphite Crucible or Graphite Block

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Summary

The wax pattern is the precursor of the finished cast restoration. As it will be duplicated exactly through investing and casting, the final restoration can be no better than its wax pattern. A successful result depends on careful handling of the wax. Strict adherence to standardized procedures ensure a good and long 3/5/13 lasting cast restoration obliterating

REFERENCES

Anusavice Skinners science of dental materials. Tenth Edition. Asgar K., Arfaei A.H. Castability of crown and bridge alloys. J Prosthet Dent 1985; 54: 60-63. Donovan T.E., White T.E. Evaluation of an improved centrifugal casting machine. J Prosthet Dent 1985; 53: 609-612.
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Eames B.W. Evaluation of

Earnshaw R. The effects of additives on the thermal behaviour of gypsum bonded casting investments part I. Aus. Dent. J. 20 : pp27, 1975. Teteruck W.R. and Mumford G. The fit of certain dental casting alloys using different investing materials and techniques. J. Prosthet. Dent. 16 : pp910, 1966. J. F. Jelenko Co: Thermotrol Technician, 34 : No.1, Winter, 1980. Neiman R. and Sarma A.C. : Setting and thermal reactions of phosphate cements. J. Dent. Res. 9 : pp1478, 1980. Allen F.C. and Asgar K : Reaction of cobalt chromium casting alloy with investments. J. Dent. Res. 45 : pp1516, 1966. Dootz E.R., Craig R.C. and Peyton F.A. : Simplification of chrome-cobalt partial denture casting procedure. J. Prosthet. Dent. 17 : pp464, 1967. Mabie C.P. : Petrographic study of the refractory 3/5/13 performance of high-fusing dental alloy investments: II

THANK YOU
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