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Casting Defects 3rd Year

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zyad reda eldahrawy
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2 views

Casting Defects 3rd Year

Uploaded by

zyad reda eldahrawy
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Casting defects

Iman Ibrahim
Lecturer of Fixed Prosthodontic Department
The laws of casting
• Every casting contains porosity
caused by solidification
shrinkage.
• Porosity occurs in the area of
casting that is last to solidify,
thus the challenge is to use
knowledge of casting science to
locate the porosity in the area
of spruing system away from
the restorations.
Casting defects
1. No casting
2. Casting defects by addition
3. Casting defects by loss (incomplete casting)
4. Porosity
5. Dark or discolored casting
6. Oversized or undersized restoration
7. Scarped or distorted restoration
1-No casting:

▪ Fracture of investment bridge and alloy escape


• Due to Thin bridge 6-8 in G.B.I
3-5 in P.B.I

▪ Gate obstruction
• Presence of Investment fragment.
• Presence of Metallic sprue former.
1-No casting:

▪ Molten alloy not properly directed during casting


• Flat crucible former.
• Improper alignment of crucible & ring during casting.

▪ Premature solidification of alloy during casting

• Thick sprue
• Inadequate casting pressure
• Cold ring
• Incompletely heated & melted alloy
2-Casting defects by addition :

a) Fins.
b) Bubbles or nodules
Large nodules
Small nodules
c) Roughs surface.
2-Casting defects by addition :

fins:
When the molten alloy fill a crack in the investment,
as a result accessory wings to the cast restoration appear,
They are called fins or frayed

• Disturbing the ring during setting of the investment


• Dropped mold
• High w/p ratio
• Rapid heating of investment (mold still wet)
• Weak investment
• Pattern too near to edge of investment
2-Casting defects by addition :

Bubbles/nodules:
Large nodule

• Due to excessive vibration.


Present at the lower surface of the wax pattern

• Due to Air entrapped during investing.


Present at any place of the casting
• Small nodule

• Inadequate vacuum.

• Improper brush technique.

• Lack of surfactant.
2-Casting defects by addition :

Rough surface:

1-Rough surface of wax pattern.


2-Increased w/p ratio.
3-Excessive surfactant (wetting agent) or
investing before complete dryness of wetting agent.
4-Investment material with large grains or
expired investment material
5-Exessive burnout temperature
(over heated investment & alloy).
3-Casting defects by loss (incomplete casting):
a) At Margins :
1- Rough margin:
-Foreign body in mold cavity.
2- Round margin (convex):
- Insufficient casting pressure and alloy heating.
-Casting in cold ring.
3-Round margin(concave):
-Entrapment of air due to:
• Less venting
• incomplete burnout of wax
• thick margin
• carbon residues from wax
-Casting of inadequate amount of alloy.
3-Casting defects by loss (incomplete casting):
b) At Thin areas :

•Due to lack of accessory Sprue (Ex: veneered surface)


4- Porosity:

Voids or pores within a substance.


• Micro → Not Seen By Naked Eye.

• Macro → Easily Identified .

Types:
• Surface Porosity.

• Sub-surface Porosity.
4- Porosity:
Surface Porosity ( External Porosity ) :
→Lead to Roughness and Galvanic Corrosion .

❑ Back Pressure .
❑ Suck Back .
❑ Micro Porosity .
❑ Surface Porosity .
❑ Shrink Spot .

Sub-surface Porosity (Internal Porosity) :

❑ Leads to Weakening of alloy .


❑ Gas Inclusion .
4- Porosity:

A) Back Pressure Porosity :

Due To Failure OF Air to escapement from Mold through pores .

Reduced By:

1-Proper w/p Ratio .


2-Proper Burnout .
3-Sufficent Casting Pressure .
4-Adequate Casting Temp.
5-Proper length of Investment
6- Using more porous invest .
4- Porosity:

B) Suck Back Pressure Porosity :

• Due to Presence of Over Heated Area (hot spot ) At Entrance of Molten


alloy → This area solidifies lastly, the shrinkage of the casting
compensated from it, thus it appears as a porous area.
• Very dangerous as it appears with polishing
4- Porosity:

C) Micro Porosity :

• Inside any cast restoration Due to Unequal Distribution


of Solidification ( Not Appear By Naked Eye ).

• Appears as Rough Restoration → Galvanic Cell →


Tarnish &corrosion .
4- Porosity:

D) Surface Porosity :
Appear as Rough surface Due to :-

1-Rough wax pattern .


2-over Heated Ring .
3-Incorrect investing .
4-High W\P Ratio .
5-Not Using Vacuum .
6-Excess Use of wetting agent.
7- Using of Investment with large grains .
4- Porosity:

E) Shrink Spot Porosity (localized ) :


Due to :

• Cast Restoration and Sprue solidification at same Time and


Compensate Shrinkage from area of connection to sprue →which
appears porous → if shrinkage is aggressive, Separation between them
.
4- Porosity:

F) Gas Inclusion Porosity :

Entrapment of Air gas in Molten Alloy due to :-

1- Using zone other than reducing zone .


2- Affinity of some alloy to absorb O2 like → (Titanium ).
3-Vapor from Heating of invest . (decomposition of Invest ).
4-Entrampment of Oxide inside Molten alloy .

G)Inclusion Porosity :
Particle of Investment Dislodged during
casting .
4- Porosity:
H) Sub-Surface Porosity:

Cause Weakness of Metal .


Due to :

• Casting of Metal in Cold Mold At which Outer layer of Metal solidify


first and Compensate Shrinkage from inside Part .

• Very Dangerous as Casting Appear accurate But porosity appear on


Finishing of Casting .
5-Dark or discolored casting:

• This phenomenon is due to the decomposition of calcium sulfate


binder of the gypsum-bonded investment due to over heating

• If base metal remake (no pickling is allowed).

• If gold:
Discoloration due to copper oxides So pickling.
Discoloration due to suffer of binder combines with copper or silver
(Gold resist pickling so remake).
Carbon contamination caused by carbon vapor from wax pattern
(Gold resist pickling so remake).
6- Oversized or undersized restoration:

Due to expansion of investment.

• Both types must be remake as they expose cervical margin (dissolves


cement & recurrent caries).

• Oversized (open margin).


• Under sized (short margin).
7- Scarped or distorted restoration:
Due to:
1- incorrect impression or die construction.
2- incorrect handling of wax pattern before investing.
3- incorrect examination >>>> stress relaxation of wax.
>>>> quality of setting & hygroscopic expansion.
4- incorrect processing of pattern in ring.
5- usage of force during removal of pattern from ring or during finishing &
polishing.
Thank you

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