CASTING PROCEDURE

Dr. Md. Tanvir Rahman

BDS (Dhaka Dental), BCS (Health)
Lecturer
Science of Dental Materials & Engineering
Dhaka Dental College
Definition

Casting is a manufacturing process where a solid is

melted, heated to proper temperature & is then forcefully
introduced into a cavity or mold which contains it in the
proper shape during solidification.

The object formed by casting procedure called “a casting”.

Example: Inlays, Onlays, crown, bridges, RPD framework.
Objectives

To prepare permanent metallic duplicate of the missing

tooth structure.
Metallic frame work

Pontics as accurately fitting as possible

Materials & instruments

Materials Instruments

 Die material  Centrifugal casting machine

 Inlay casting wax

 Sprue former
 Crucible former
 Investment material
 Casting ring
 Ring liner
 Crucible
 Inlay Casting Wax Crucible Former
Sprue Former

Sprue former
Casting Ring
Ring liner

Crucible Centrifugal machine

Steps of Casting Procedure

 Tooth or teeth preparation.

 Taking impression of prepared teeth.

 Preparation of die with type ⅠV or V stone

 Preparation of wax pattern with casting wax.

 Attachments of wax pattern with sprue former.

 Placements of the ring liner inside the casting ring.

 Placements of other end of sprue former at the midpoint

of crucible former.
Continues…

 Placements of casting ring over the crucible former.

 Investing the wax pattern after spraying non foaming

detergent over the pattern.

 Burn out of the wax.

 Casting.

 Quenching & recovery the cast

 Cleansing the cast by pickling solution.

 Polishing of the cast.

Casting Procedure
Materials of casting with functions

Die materials: Type ⅠV or V stones.

Inlay casting wax: Type ⅠⅠ inlay wax is mainly used because

modulus of elasticity is high & prevent distortion during investing

procedure. Other wax can be used with precaution to prevent

distortion.
 Continues…
Sprue:
Materials of sprue former are:
i. Special wax supplied as rope form of different diameters for
selection.
ii. Hollow stain less still wires of different diameters & lengths. For
easy removal from investment it coated with inlay wax by dipping
them into molten wax & it attached with wax pattern.

Functions:
• it make a channel for elimination of wax during burn out process.

• It makes passage for entry of molten alloy during casting.

• It acts as a reservoir of molten metal which compensate alloy shrinkage

during solidification.
Continues…
Ring liner: is placed inside the ring. Previously asbestos liner were used but recently
it is banned as it is carcinogenic . Recently non asbestos liner are used. They are-
• Fibrous ceramic aluminous silicate.

• Cellulose (paper).

• Ceramic-cellulose combination.

Function:
• Acts as a cushion for the setting investment & facilitates the mould expansion.

• Acts as a thermal insulator & prevents the heat loss when it is transferred from the

furnace to cast.
• Facilitates the easy recovery of the cast from the casting ring.

• Facilitates the thermal expansion of the mould

• Facilitates easy escape of occluded gas.

Casting procedure or technique

• Die preparation:

Die is prepared by die stone. For casting gold alloy or newer

type of base metal alloy it is better to use type V stone as it can provide
more expansion and help to compensate cooling shrinkage.

• Wax pattern fabrication:

A pattern for final restoration is made by inlay casting wax.

Before making pattern, a Die lubricant is applied to separate the wax
pattern from the die. Care is to be taken for not distorting wax pattern.
Continues…

• Attachments of sprue former:

A sprue former made of wax, plastic or metal is attached to the

bulkiest point of wax pattern. It should be placed such way that removal
of sprue former directly in line with its path of withdrawal from the die.
During removal any resistance, may cause distortion of pattern.
Distorted pattern should be discarded. Thickness of the sprue is
proportion to wax pattern (1.3mm-2.6 mm). A piece of wax 1 mm away
from pattern is attached to act as a reservoir.
Continues…

The length of sprue former should be long enough to position the

pattern in casting ring. The distance between upper extremity of
wax pattern & end of casting ring should not be more than 6 mm.
The wax pattern with sprue former is attaching to crucible former.

Diameter & attachments of sprue former is very important for

successful cast:
o Sprue diameter: The diameter of sprue related to the thickness of the
wax pattern. If sprue is small then molten metal will solidify within the
sprue resulting insufficient metal flow and cause incomplete casting.
Larger diameter sprue cause rough surface, suck back porosity or
localized shrinkage porosities or distortion of thin section.
Continues… (Diameter & attachments of sprue former is very important
for successful cast)

o Length of sprue former: unusually larger sprue former cause pre-

solidification of molten metal within the sprue which will restrict the
smooth flow resulting incomplete casting. Too short sprue cannot vent
gases. These gases remains in the mould and prevent the flow of
molten metal. The cast will suffer from suck back porosity, rough
surface & distortion of thin surface.
o Sprue attachments: should be attached to the bulkiest point, if attach

on the thin section of pattern, localized shrinkage porosity will result.

o Reservoir: A reservoir is made 1-2 mm away from the attachments of

sprue with the pattern. It will reserve the molten metal & will provide
molten metal to prevent solidification shrinkage.
Continues… (Diameter & attachments of sprue former is very
important for successful cast)

o Direction of sprue former: Sprue axis should not be directed

towards the thin section of the cast. This will damage the thin

section of the cast as casting force is highest in this direction.

o Flaring of the sprue former: Flaring of the sprue is done for

facilitating the molten metal supply when solidification starts.

Acts as reservoir, reserve molten metal and facilitates the flow of

molten metal to the pattern & thus prevents the solidification

shrinkage.
Continues…

• Casting ring liner:

A ring liner is placed inside to casting ring. Liner should

be short on one end or both end of the ring. The short ring liner
will help to restrict both longitudinal and hygroscopic expansion.
Casting liner should not overlap and dry liner is tacked in one
place. Before placement of ring liner it should immersed in water
& shaken off the excess water. It provides semi hygroscopic
expansion to the mould.
Continues…
• Investing Procedure:

Wax pattern should be free from grease, debris or oil. A wax

cleaner or diluted synthetic detergent is sprayed over the pattern & then
pattern is air dried.

Then mixing of investment materials carried out by vacuum mixer to

remove any air bubble. For mixing in bowl liquid is pour gradually.

Pouring of the mix: After the completion of mixing, the pattern is hand
invested or vacuum invested. Before pouring the mix, the pattern is finely
painted with the mix by a brush. Then casting ring is placed on crucible
former & rest of the investment is vibrated slowly in the ring. With vacuum
mix , casting ring is placed on the vibrator & mix is poured on the ring.
Because of vibrator entrapped air will gradually come to the surface.
Continues…

• Burn out of wax (wax elimination) & thermal expansion:

The casting ring is placed in furnace at room temperature wile

it is still wet. For gypsum investment burnout temperature can be either
500˚C for hygroscopic expansion or 700˚C for thermal expansion
technique.

Another suggestion to place the casting ring in the furnace at 315˚C for
30 mins and following rapid heating to the final burn out temperature.

There are some investments which may place in the furnace directly at
burn out temperature, held for 30 mins & cast.
Continues…

Another method of burn out process:

I. Place the ring in the room temperature furnace.
II. Raise the temp gradually upto 400˚C within 20 mins.
III. Maintain this temp for 30 mins.
IV. Next raise temp upto 700˚C within 30 mins.
V. maintain this temp for 30 mins.
Now mould is ready for cast.
Continues…

Burnout is one of the most important process because:

o Total elimination of wax: By slow heating total wax of wax pattern

must be burn out. Any remaining residue of wax cause rough casting.
o Rapid heating: Rapid heating must be avoided. Water within the

investment will rapidly converted into steam & will try to come out
from the investment with high pressure. This may cause fracture of
investment. Besides inner surface of investment will remain wet &
outer surface will be dry and rigid. Two different type of stress will
developed between inner & outer surface; tensile & compressive
stress. This also may cause fracture of the investment.
Continues… (Burnout is one of the most important process because:)

o Over heating: over heating causes too much expansion of

mould causes disintegration of investment. This will cause

tarnish of gold alloys, rough casting.
o Prolonged heating: prolonged heating may cause cracks &

fracture of investments. All precautions should be taken to save

the investments from the fracture especially mould surface.
Fracture investment causes rough surface even fracture cast
resulting failure.
Continues…

• Casting:

Investments contracts on cooling, under average condition in 1 min

no noticeable loss in dimension

The casting machine spring is wounded in 2 to 5 turn. Usually 2 and half

turn. A crucible is attached on the broken arm.

The alloy is melted in the crucible by torch flame. Torch flame is generated
by natural gas & air. The reducing zone of flame is used. At casting
temperature, molten alloy is light orange. For more fluidity & prevent
oxidation of molten alloy reducing flux should be sprinkled. For Gold alloy it
also prevent porosity of the cast.
 Continues…
• Recovery the cast

After casting ring is removed & quenched in water, as soon as

button exhibits dull red. This process help to easy removal from the
investment & easy polishing.

• Cleaning the cast

pickling solution is to remove dark film of oxide from the cast.

Pickling consists of 50% hydrochloric acid which help to remove any
residual investments & oxide coating. Sulphuric acid is alternative to it.

The best method is placed a cast into test tube or dish & then pour pickling
over it then heated blow its boiling point. After pickling is completed cast is
polished.
Causes of incomplete casting:
 Use of insufficient alloy.

 The alloy is not able to enter the thin portion of the mould.

 The mould is too cold, causes premature solidification of alloy.

 Foreign matters, such as particle of fluxes or investment, unburnt waxes

block the sprue.

 There is back pressure of gases in the mould.

 The alloy is not fully molten.

 Too low casting force is used.

 Metal having poor castabilitiy. (High viscosity)

 Incomplete de waxing

 Sprue is too thin or long causing pre-solidification of molten alloy within the

sprue may block the sprue

Dimension Errors

Problem Cause Method of avoiding faults

Casting too Excessive mould Use correct temp with correct
large expansion investment materials
Casting too Too little mould Heat the mould sufficiently
small expansion
Distorted Distorted wax pattern Correct handling the wax
casting
Causes of rough surfaces & fins
problem Cause Method of avoiding fault

Rough Investment break down 1. Avoid overheating of mould

surfaces Air bubble on wax pattern 2. Correct vacuum investing technique
Weak surface of investment 3. Avoid high W/P ratio
( high W/P ratio)

Rough wax pattern Wax pattern should be smooth before investing

Coarse investment powder particle Particle should be fine & regular size.

Insufficient wetting of wax pattern Sprayed well with non foamy detergent

Improper method & incomplete de- Proper de-waxing method

waxing, too rapid, prolonged & too rapid, prolonged & overheating heating are
overheating heating during burnout highly contraindicated.

High casting force Should be avoided because high force will abrade
the walls of mould

Fins on Cracking of investment materials Avoid too rapid heating

casting
Porosities

According to Philips:
 Localized shrinkage porosity

 Micro porosity

 Trapped gases

 Pinhole porosity

 Gas inclusion

 Subsurface porosity

 Residual air.
Causes of porosities
problems Cause Method of avoiding Faults
Irregular voids Shrinkage on cooling 1. Use sprues of correct thickness.
alloy 2. Attached the sprue at the bulkiest
portion of pattern.
3. Reservoir sufficiently near the pattern

Irregular voids Inclusion of particles Heat the mould upside down so that
of investment alloy particle fall out of the mould
Spherical voids Occluded gas on Avoid over & prolonged heating
molten alloy
Rounded margin; Back pressure effect; 1. Use sufficient casting force.
Regular large air unable to escape 2. Use investment of adequate
voids from the mould permeability.
3. Place pattern no more than 6-8 mm
away from end of casting ring.

Porosity Turbulent flow of Correct placement of sprues

molten alloy into the
mould
Porosities in a nut shell

Localized Shrinkage: Caused by premature termination of the flow of

molten metal during solidification. The liner contraction of noble metal
changing from liquid to solid at least 1.25%. Therefore continuous feeding of
molten metal from sprue must occur to make up this shrinkage during
solidification. If the sprue freezes in its cross section before this feeding, a
localized shrinkage porosity occurs.

Site: Generally near the sprue casting junction, may also occur externally, in
the crown interior near the area of sprue.

Micro porosity: this porosity also occur on solidification shrinkage but

generally present in fine-grain alloy casting when solidification too rapid. This
porosity is seen in the form of small, irregular voids.
Continues… (porosity)
Pin hole porosity: Both pin hole & gas inclusion porosities are related to the
entrapment of gas during solidification. Both are characterized by a spherical
contour but different in size. The gas inclusion porosity is much larger than pin
hole porosity.
Causes: Many metal dissolves occluded gas during melting time like copper &
silver dissolves oxygen in large amounts, PT & PD has great affinity for
hydrogen & oxygen. On solidification the gas is expelled and cause pinhole
porosity. The larger voids are caused by entrapped gas that is mechanically
trapped during molten metal in the mould or gas that is incorporated during
casting procedure. Larger spherical porosities caused by poorly adjusted torch
flame, not using reducing zone of flame.
Site: Porosity that extended to the surface usually in the form of pin point holes.
After polish of surface other pin holes appear.
Continues… (porosity)

Entrapped air porosity of the inner surface of casting : It is also

called back pressure porosity. It can produce large concave depression.
Cause: this is caused by inability of the air in the mould to escape through the
pores of investments or by the pressure gradient that displaces the air pocket
towards the end of investment via the molten sprue. This entrapment is
frequently found in a “pocket” at the cavity surface of a crown. Occasionally
found on the outside surface when casting temp or molten temp is so low that
solidification occurs before entrapped air can escape.

Subsurface porosity: Sub surface porosity may caused by the

simultaneous nucleation of solid grains & gas bubble at the first moment that
the alloy freezes the mould walls. This type of porosity can be diminished by
controlling the rate at which the molten metal enters the mould.
Continues… (porosity)

Solution: Proper burn out, adequate mold & casting temperature, a

sufficiently high casting pressure & proper L/P ratio can help to
eliminate entrapped air porosity. The thickness of investment between
the tip of pattern and the end of the ring not be greater than 6 mm.
Black Cast

Oxygen is dissolved by many metal during its melting. Oxygen is responsible for porosity.
Casting that are severely contaminated with gases usually became black when the are removed
from investment.

Incomplete elimination of the wax pattern as a result of low heating may cause the black cast.
Remnants of wax (Carbonized) will get stick to the cast resulting black cast.

Investment of Gypsum can be decomposed by overheating ( more than 700C ) produce Sulphur
which cause black cast of gold

Solution: These type of porosity can be minimized by pre melting the gold alloy on a graphite
crucible or a graphite block. If the alloy has been used before & by correctly adjusting &
positioning the torch of flame during melting. Pickling solution can also be used. Black cast
caused by Sulphur & oxygen is difficult to remove by pickling solution. Caused by wax can be
removed by heating over flame.
Marginal fit is necessary for long term success

Well adapted margin is one of the determining factors of success

of cast. If the gap is 60µm which is the diameter of hair will not
catch explorer tip. Crown are fitted with luting cement. If the
accuracy of margin is higher like 25µm or less then the layer of
cement is very thin & distortion of the cement is negligible. But if
margin accuracy is more than 60 µm then there will be more
distortion of cement eventually opening of the margin. In this gap
food, bacteria will accumulate which leads to secondary caries,
ultimately failure of cast.