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Casting Defects

This document discusses various defects that can occur in dental castings, including distortion, discoloration, surface irregularities, porosities, and incomplete casting. It describes the causes of each defect and methods for avoiding or minimizing the defects, such as proper wax manipulation, flux application, investment technique, heating procedure, alloy composition and processing.

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Bhagya
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
11 views

Casting Defects

This document discusses various defects that can occur in dental castings, including distortion, discoloration, surface irregularities, porosities, and incomplete casting. It describes the causes of each defect and methods for avoiding or minimizing the defects, such as proper wax manipulation, flux application, investment technique, heating procedure, alloy composition and processing.

Uploaded by

Bhagya
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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 DISTORTION

 DISCOLORATION

 SURFACE IRREGULARITIES

 SURFACE ROUGHNESS

 POROSITIES

 INCOMPLETE CASTING
DISTORTION
 CAUSE----DUE TO DISTORTION OF THE WAX
PATTERN

 DURING---PLACEMENT
 ---SPRUE ATTACHMENT
 ---PLUS CONTACT PLACEMENT
 ----DELAY IN WAX PATTERN INVESTING
MINIMIZED BY—

 PROPER WAX MANIPULATION

 INVESTING PATTERN IMMEDIATELY


DISCOLORATION

CAUSES
 ---OXIDES IN MOLTEN METAL AND LACK OF
FLUX
 ---USE OF YELLOW ZONE OF HEATING TORCH
 ---UNDERHEATING OF INVESTMENT RING---WAX
REMNANTS ARE PRESENT---DISCOLORS CASTING
 ---OVERHEATING OF GYPSUM INVESTMENT
 ---SOLDERING—DISCREPENCY BETWEEN PARENT
AND SOLDERED METAL—GALVANIC CELL
FORMED—DISCOLORS CASTING
 MIXING OF OLD AND NEW CASTING
 MERCURY CONTAMINATION

AVOIDED BY
 FLUX APPLICATION TO MOLTEN METAL
 AVOID EITHER UNDERHEATING OR
OVERHEATING OF THE INVESTMENT
 USING THE BLUE REDUCING ZONE FOR
HEATING METAL
 DURING MIXING OF OLD AND NEW CASTING---
KEEP IT AT 50%
 AVOIDING MERCURY CONTAMINATION

SURFACE IRREGULARITIES
(larger,severe ,irregular distribution)
NODULES/BLEBS

CAUSE----DUE TO AIR BUBBLE INCORPORATION


DURING INVESTING

AVOIDED BY---
 WASHING THE WAX PATTERN WITH SOAP
SOLUTION
 SURFACTANT APPLICATION
 VIBRATION OF MIX , VACUUM MIXING
 DOUBLE POUR TECHNIQUE OF INVESTING
BLEBS AND VEINS
VEINS/RIDGES
 CAUSE—DUE TO WATER FILM INCORPORATION
(AT THE WAX –INVESTMENT INTERFACE)
DURING INVESTMENT

 AVOIDED BY
 ---PROPER POWDER : LIQUID RATIO
 ---DOUBLE MIX TECHNIQUE
 ---AVOID EXCESS VIBRATION
FINS /SPIKES
CAUSE—DUE TO CRACKING OF INVESTMENT ON
RAPID HEATING

AVOIDED BY
 HEATING GRADUALLY FROM ROOM
TEMPERATURE TO 700 O C
OTHER CAUSES OF SURFACE
IRREGULARITIES

 INVESTING MANY PATTERNS IN THE RING—THE


INVESTMENT INBETWEEN IS THIN AND CANNOT
TAKE THE CASTING PRESSURE—IT SHATTERS---
RESULTS IN SURFACE IRREGULARITIES
 EXCESSIVE CASTING PRESSURE---ABRADES THE
MOLD SURFACE—SURFACE IRREGULARITY ON
CASTING
 INCORPORATION OF FOREIGN BODY

CAUSE---CHIPPED OFF INVESTMENT AT SHARP


AXIOPULPAL LINE ANGLE
----CORRODED SPRUE

 AVOIDED BY----AVOID CORRODED METAL SPRUE


-----ROUNDING OF AXIOPULPAL LINE
ANGLE IN THE CAVITY PREPARATION
SURFACE ROUGHNESS
(milder,smaller and regular in distribution)
CAUSES
 --COMPOSITION OF THE INVESTMENT
MATERIAL
(large size of silica fillers)

 LACK OF APPLICATION OF SURFACTANT---


improper adaptation of wax –investment interface
 PROLONGED HEATING---surface investment
starts to shatter

 HIGHER WATER: POWDER ratio—weaker


investment---shatters on application of
casting pressure
 HIGHER TEMPERATURE OF MOLTEN METAL----
oxides are picked up
AVOIDED BY---melting alloy only to 100-
150 0 c over the casting ring
temperature

 EXCESSIVE CASTING PRESSURE


POROSITIES
 CANNOT BE TOTALLY ELIMINATED BUT
COULD BE MINIMISED

CAN OCCUR BOTH ON


 INTERNAL(decreases strength of casting,
discoloration and if extends to the surface, it causes
plaque accumulation and secondary caries) and
 EXTERNAL (surface roughness, tarnishes and
corrodes—difficult to finish and polish)
CLASSIFICATION
DEPENDING ON THE CAUSE--
 A)SOLIDIFICATION DEFECTS
1)LOCALISED SHRINKAGE POROSITY
2)MICROPOROSITY

 B)TRAPPED GASES
1)PIN HOLE POROSITY
2) GAS INCLUSION POROSITY
3)SUB SURFACE POROSITY

 C)RESIDUAL AIR
BACK PRESSURE POROSITY
SOLIDIFICATION DEFECTS
LOCALISED SHRINKAGE POROSITY
CAUSE—PREMATURE TERMINATION OF THE FLOW
OF METAL DURING SOLIDIFICATION

OCCURS AT—JUNCTION OF WAX PATTERN AND


SPRUE

DUE TO---NARROW SPRUE—THUS MOLTEN METAL


STARTS TO HARDEN BEFORE ENTERING THE
MOLD SPACE
AVOIDED BY—PROPER SPRUE DIAMETER
---RESERVOIR PLACEMENT
SUCK BACK POROSITY
 IT IS A LOCALISED SHRINKAGE POROSITY THAT OCCURS
EXTERNALLY ON THE INTERIOR SURFACE NEAR THE AREA
OF THE SPRUE, OPPOSITE A HOT SPOT (a higher mold
temperature area created where the hot metal impinges onto the
mold)

 OCCURS AT---INNER SURFACE OF CASTING OPPOSITE


THE AXIOPULPAL LINE ANGLE

 DUE TO ---HOT SPOT CAUSES THE METAL IN THAT


REGION TO FREEZE LAST RESULTING IN A SUCK BACK
POROSITY
 AVOIDED BY—FLARING THE POINT OF SPRUE
ATTACHMENT
 ---REDUCING THE MOLD—MOLTEN METAL
TEMPERATURE DIFFERENTIAL (by 300c )
MICROPOROSITY
 OCCURS FROM SOLIDIFICATION SHRINKAGE

 SEEN IN
---- FINE GRAIN ALLOY CASTINGS WHERE
SOLIDIFICATION IS VERY RAPID AND CREATES
MICROVOIDS

-----RAPID SOLIDIFICATION IF MOLD OR CASTING


METAL TEMPERATURE IS LOW

 SEEN AS---SMALL IRREGULAR VOIDS


DUE TO TRAPPED GASES
PIN HOLE POROSITY
GAS INCLUSION POROSITY

 DUE TO—GAS ENTRAPMENT DURING MELTING --


-WHICH GETS EXPELLED DURING
SOLIDIFICATION

 SEEN AS—SPHERICAL POROSITIES ( GAS


INCLUSIONS BEING LARGER INSIZE)

 MINIMIZED BY—
---PREHEATING METAL ON GRAPHITE CRUICIBLE
--PROPER ADJUSTING AND POSITIONING OF THE
TORCH FLAME (blue reducing zone to be used)
SUBSURFACE POROSITY

 CAUSE—SIMULTANEOUS NUCLEATION OF
METAL GRAINS AND GAS BUBBLES AS THE
MOLTEN METAL FREEZES AT THE WALLS
DUE TO RESIDUAL AIR
BACK PRESSURE/ ENTRAPPED AIR
POROSITY
 SEEN ON –INNER SURFACE OF CASTING AS LARGE
CONCAVITIES /OUTER SURFACE IF MOLD /CASTING
TEMPERATURE IS LOW THAT SOLIDIFICATION OCCURS
BEFORE AIR ESCAPES

 DUE TO---ENTRAPPED AIR IN THE MOLD

 SEEN IN—USE OF DENSE INVESTMENTS


--VACUUM INVESTED
--MOLD CLOGGED BY CARBON
 AVOIDED BY—PROPER BACK UP INVESTMENT THICKNESS
---VENT PLACED IF BACK UP INVESTMENT IS THICK
---LARGER FILLER PARTICLE SIZE
INCOMPLETE CASTING
CAUSES

 INSUFFICIENT VENTING OF THE MOLD(due to back


pressure exerted by air in the mold)
Avoided by---proper casting pressure applied for 4 sec
Seen as –rounded incomplete margins

 WAX PATTERN NOT MELTED OUT( combination of molten


alloy with wax produces gases causing back pressure)
Seen as---rounded margins ,shiny (due to reducing environmemt
created by carbon monoxide)
 INADEQUATE MELTING OF ALLOY

 DISLODGEMENT OF WAX PATTERN

 NARROW SPRUE---metal not flowed into mold


space completely---(avoided by---Reservoir
placement)
 FOREIGN BODY BLOCKAGE

 INCORPORATION OF FLUX

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