Casting Defects

CASTING DEFECTS
Dr.Kamran Asadullah Dem/Lecturer Science of Dental Materials
DEFECTS IN CASTING
Defective casting may be due to various reasons and can be avoided or minimized by strictly following the fundamental rules and procedures.
CLASSIFICATION OF CASTING DEFECTS

1. 2. 3. 4. Distortion Surface roughness Porosity Incomplete casting
In addition, a casting can be contaminated due to: Over heating the alloy. Use of oxidizing zone of the flame. Failure to mix flux. 5. Sulfur compounds, formed by the breakdown of the investment when the ring is overheated.
DISTORTION
Distortion of casting is usually due to distortion of wax pattern. Some distortion of wax occurs when the investment hardness or due to hygroscopic & setting expansion. Some distortion of wax occurs during manipulation, b/c of the release of stresses.
Minimize distortion by:

Manipulation of wax at high temperature. Investing pattern within 1hr after finishing. if storage is necessary, store in refrigerator.
SURFACE ROUGHNESS
Surface roughness can be usually be traced to:
1. Air bubbles on wax pattern cause nodules on the casting.
Avoid by:
Proper mixing of investment. Vibration of mix or by vacuum investing. Application of wetting agent.
2. Too rapid heating cracks the investment resulting in fins.
Avoid by:
Heat the casting ring gradually 700 C (in at least 1hr). 3. W/P ratio: Higher W/P ratio gives rougher casting. Large particle size of investment has the same effect.
O
Avoid by:
Using correct W/P ratio & select investment of correct particle size.
4. Prolonged heating causes disintegration of mould cavity liberating sulfur or its compounds.
Avoid by:
Complete the casting as soon as the ring is heated & ready. 5. Over heating gold alloy has the same effect. They combine with the metals in gold alloy forming a sulfide film producing a dark casting, which cannot be cleaned by pickling. 6. Too high or too low casting pressure.
Avoid by:
Using 15lbs/sq inch of air pressure or 3 to 4 turns of centrifugal casting machine.
7. Composition of the investment, proportion of the quartz & binder influences the surface texture of casting. Coarse silica will give coarse casting.
8. Foreign body inclusion shows sharp, well- defined deficiencies. Inclusion of flux show bright concavities.
INCOMPLETE CASTING
Many factors are involved in incomplete casting.
A. Insufficient amount of alloy:

If the quantity of the molten alloy is small the molten metal or alloy will not reach to every part of the mould & causes in complete casting.
Overcome:
Correct quantity of molten alloy is used.
B. Number & Size of sprue: If the no. & size of sprue are small, molten metal will not reach in every part, causing incomplete casting.
Overcome:
Thick & more than one sprue are used.
C. Attachment of sprue:
If the sprue attached to the thin part of the pattern may cause incomplete casting.
Overcome:
Sprue should be attached to the most bulky part of the pattern.
D. Back pressure of Gases:

Gases present in the mould may cause in complete casting.
Overcome:
By using the investment material which is porous & allow the gases to escape.
E. Centrifugal force:
Molten metal enters into the mould slowly & may become hard before reaching every part of mould f the arm of casting machine is small. Arm small = Centrifugal force small Arm Large = Centrifugal force large
F. Presence of dust particle:

Dust particle & investment particle present in the mould cavity may block the way of entrance of molten metal causes incomplete casting or may be embedded on the surface of the casting.
G. Temperature:
If the mould is cool the metal become hard causes incomplete casting.
Overcome:
Mould should be warm at the time of insertion of metal or alloy.
POROSITY
Porosity may be internal or external. External porosity can cause Discoloration of casting. Severe porosity at the tooth restoration junction can even causes secondary caries. Internal porosity weakens the restoration.
Porosities are classified as:

1. 2. 3. Those caused by solidification shrinkage: Localized shrinkage porosity irregular Suck back porosity in Micro porosity shape Those caused by gases: Pin hole porosity usually Gas inclusions spherical Subsurface porosity in shape Those caused by air trapped in the mould (Back pressure porosity)
A. Irregular voids: Cause:

1. Due to shrinkage on cooling of alloy. 2. Inclusion of particles of investment material.
Overcome:
By using the sprue of correct thickness. By Placing sprue at the bulkiest portion of the pattern.
B. Spherical voids: Cause:

1. Occluded gases in the molten alloy & released when set.
Overcome:
Heat mould upside down so that the gases come out from the mould. Ovid over heating & prolonged heating of alloy.
C. Rounded margins:
Regular large voids.
Causes:
1. Back pressure effect: air unable to escape from the mould.
Overcome:
Using adequate casting force. Use investment of adequate porosity. Place pattern not more than 6 to 8 mm away from the end of the ring. Providing vents in large casting.
D. Contamination: Causes:
1. Due to oxidation when molten alloy is over heated. 2. Use of oxidizing zone of the flame. 3. Failure to use flux. 4. Due to formation of sulfur compounds.
Overcome:
Not overheating the alloy. Use reducing zone of the flame. Use flux.
DIMENSIONAL ERRORS IN CASTING

PROBLEM CAUSE PRECAUTIONS
Casting too Excessive Use correct temperature large expansion Use correct investment
Casting too small

Distorted casting
Too little mould expansion

Distorted wax pattern
Heat the mould sufficiently

Correct handling of wax
ROUGH SURFACE & FINS ON CASTING PROBLEM

Rough surface
CAUSE
Investment breakdown
PRECAUTION
Avoid overheating of mould & alloy. Correct use of wetting agent. Vacuum investing Avoid too high W/P ratio.
Fins on casting
Avoid dilution of Weak surface investment from of investment application of too much wetting agent Cracking of Avoid rapid heating of investment investment
Air bubbles on wax (nodules on casting)
POROSITY
PROBLEM
Irregular voids
CAUSE
Shrinkage on cooling of alloy
PRECAUTION
Use correct sprue thickness. Attach sprue at thickest part of wax pattern Use reservoir. Inclusion of foreign Heat mould upside down so that particles particles fall out. Occluded gases in molten alloy Avoid overheating & prolonged heating of alloy.
Spherical voids
Rounded margins: regular large voids
Back pressure Use adequate casting force. effect: air unable to Use porous investment. escape from Avoid wax residue in mould. mould. Place pattern 6 to 8 mm away from the end of the ring. Use vents.
Turbulent flow of molten alloy into the mould. Correct placement of sprue.
Porosity

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CASTING DEFECTS

Dr.Kamran Asadullah Dem/Lecturer Science of Dental Materials

CLASSIFICATION OF CASTING DEFECTS

Minimize distortion by:

1. Air bubbles on wax pattern cause nodules on the casting.

2. Too rapid heating cracks the investment resulting in fins.

A. Insufficient amount of alloy:

D. Back pressure of Gases:

F. Presence of dust particle:

Porosities are classified as:

A. Irregular voids: Cause:

B. Spherical voids: Cause:

DIMENSIONAL ERRORS IN CASTING

Casting too small

Too little mould expansion

Heat the mould sufficiently

ROUGH SURFACE & FINS ON CASTING PROBLEM

Air bubbles on wax (nodules on casting)

Rounded margins: regular large voids

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