Good

Morning
1
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GUIDED BY :

Dr. AJAY SAXENA Dr. MANOJ CHANDAK

(Prof. & Guide) (H.O.D & Prof.)

Dr .Pradnya Nikhade Dr. N. U Manwar

(Prof.) (Prof.)

Dr. Anant Heda Dr. Anuja Ikhar

(Reader) (Reader)

Presented by Dr. Abhilasha dass

Contents

Introduction
History
Preparation of a die
Wax Pattern fabrication
Sprue Former
Reservoir
Casting Ring liner
Investing
Burnout
Lost wax Technique
Crucibles
Casting
Casting machines
Cleaning of casting
Take home message

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Sr.no. Learning objective Domain Level Criteria

1 Steps in casting procedure Cognitive Must know All

2 Preparation of a die Cognitive Must know All

3 Cognitive Must know All

Wax Pattern fabrication

4 Sprue former Cognitive Must know All

5 Casting Ring liner Cognitive Must know All

6 Investing Cognitive Must know All

5
7 Burnout Cognitive Must know All

8 Lost wax Technique Cognitive Must know All

9 Crucibles cognitive Must know All

10 Casting machines cognitive Must know All

11 Finishing & polishing cognitive Must know All

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Introduction :
Casting is the process by which a wax pattern
of a restoration is converted to a replicate in a
dental alloy. The casting process is used to make
dental restorations such as inlays, onlays,
crowns, bridges and removable partial
dentures.
In dentistry the resulting casting must be an
accurate reproduction of the wax pattern in
both surface details and overall dimension.

7
 Reproducing the wax up in metal with
predictable results has always been a
challenge.

Small variation in investing or casting can

significantly effect the quality of the final
restoration.

Successful castings depend on attention

to detail and consistency of technique.
8
History
In approximately 500 BC, the Etruscans produced bridges made
of soldered gold bands.
The most ancient dental prosthesis fabricated from gold wire was
found in Egypt and dated as far back as 2500 BC.

Copper was cast in Mesopotamia about 3000 B.C.

The oldest dental castings were gold inlays found in teeth from
the natives of Ecuador in about first Century AD.

11th Century A.D Theophilus Described lost wax

technique, which was a common practice in jewelry.

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 The renaissance craftsman and sculptor Benvenuto Cellini
(1500-1571) in his autobiography described his method of
casting in both gold and bronze by coating his finely detailed
wax model with a reinforced refractory shell.

1558 B. Cellini attempted use of wax and clay for

preparation of castings.

1898- Dr. Philbrook demonstrated the 1st cast gold inlay in the
Dental Society.

1903 Lentz cast occlusal surfaces to banded gold crowns by

the lost wax method of mould formation but apparently did not
apply his technique to the fabrication of cast inlays.

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 1907- Introduction of lost wax technique by W.H Taggart.

1910 Van Horn introduced a different method of

compensation recommending that the wax pattern be
invested at a temperature equal to mouth temperature.

1928 The low heat casting technique was finally abandoned

when Coleman published his research paper No.32 for the
United States National Bureau of Standards in which he
demonstrated the great shrinkage which occurred when
investment is cooled after heating.

11
 Weinstein in 1929 found that adding boric acid to
customary investment mixtures prevented the shrinkage.

Sweeney, Paftenbarger (1930-33) studied use of

cristobalite as a refractory in dental casting investment
and found that a cristobalite based investment (75%
cristobalite & 25% plaster) heated to temperatures
between 400C and 800C produced dimensionally
accurate castings.

1942-Sonder- recognised thermal expansion of

investment was greatly inhibited by rigid metal casting
ring- advocated lining with soft asbestos.

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 1934- Classification of gold based casting
alloys.

Goldberg (1937) recommended the use of

the wax with 0.1% Contraction for the direct
technique and the wax with 0.38% contraction
for the a patterns made on a die at room
temperature in the indirect technique.

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 1945- George D. Estes, introduced the vacuum investing
technique to prevent formation of air bubbles on the surface
of the wax.

1949- Moore and Walt developed phosphate bonded

investment
1950-development of resin veneers for gold alloys

1959 Asgar & Peyton stated that flaring should

occur at the sprue/ wax pattern junction.
1959 - Strickland et al stated the importance of
the type, shape location & direction other than the
size of the sprue .

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 1959 - Morrison and Warmick reported the findings of
ethyl silicate refractory material for dental use.

1968-Pd based alloys alternatives for gold

1971- Ni based alloys alternatives for gold

1980s-Introduction of all-ceramic technology

Moore (1993) discovered by the addition of chlorides to

investments he could obtain a thermal expansion of as
much as 1.1% from quartz based investment.

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 Definition
Casting is defined as something that has been cast
in a mold, an object formed by the solidification of
a fluid that has been poured or injected into a
mold.(GPT)

Casting is the process by which a wax pattern of

a prepared tooth is fabricated and converted to
its metallic replica(Rosenteil)

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Objectives of casting :

1) To heat the alloy as quickly as possible

to a completely molten condition.
2) To prevent oxidation by heating the
metal with a well adjusted torch .
3) To produce a casting with sharp details
by having adequate pressure to the well
melted metal to force into the mold.

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STEPS IN MAKING A CAST
RESTORATION

1. TOOTH PREPARATION /CAVITY

PREPARATION
2 . IMPRESSION
3. DIE PREPARATION
4. WAX PATTERN FABRICATION
5. SPRUING
6. INVESTING
7.BURNOUT
8.CASTING
9.CLEANING & POLISHING
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Die

Defined as the positive reproduction of the form of the prepared

tooth in any suitable substance in which inlays, crowns & other
restorations are made.

IDEAL REQUIREMENTS
Accurate reproduction of the fine details
Dimensional accuracy
Good strength & hardness
Ease of use
Abrasion resistance
Relatively inexpensive

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 PREPRATION OF MASTER DIE :

Commonly used die materials-

Type IV gypsum product - 0.1% (setting
expansion)
Type V gypsum product - 0.3% (setting
expansion)

Disadvantage- Susceptibility to abrasion

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Means to increase abrasion
resistance of die :
-Silver plating
-Coating surface with die
hardener
- Adding die hardener to
gypsum

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Die spacer
Used to provide relief space for cement.
Applied within 0.5mm of the preparation finish line to provide relief
for the cement luting agent.

Example- resins (most commonly used)

- model paint
- colored nail polish
- thermoplastic polymers
dissolved in volatile solvents.

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Diestone/investment combination
In this, die material and investment medium have a
comparable composition
Divestment a commercially available gypsum bonded
material .
Divestment is mixed with colloidal silica and die is made
from this mix & wax pattern is constructed.
Advantage- It eliminate possibility of distortion
of wax pattern while removing it from die .

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OTHER DIE MATERIALS

Amalgam
Acrylic resins (shrinkage 0.6%)
Polyester resin
Epoxy resins (less shrinkage then
acrylic resins0.1to0.2%)

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ELECTROFORMED DIES :

These dies have high strength, hardness &

excellent abrasion resistance.

First step Treating the surface of impression

material so that it conducts electricity. This process
is referred as METALLIZING.

PROCESS : A thin layer of metal, such as silver

powder, is deposited on the surface of impression
material.

Example : Bronzing powder

aqueous suspensions of silver powder
powdered graphite
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ARRANGEMENT IN ELECTROPLATING BATH

~Impression- act as cathode

Electroplating bath solution- silver cyanide or
silver nitrate solution
(better details)
~Silver plate- act as anode

Electric current of 5-10 mA/cm square of cathode is

passed for 10 hour.

The impression that contains the electroformed die

surface is then filled with dental stone. When the
stone hardens, it is mechanically locked to the
rough interior of the electroformed metal shell.

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 Wax pattern fabrication
- It is contouring of wax
pattern into desired shape and
form.
- All aspects of final
restoration are incorporated
into the wax pattern
- Shortest time should elapse
between the time the pattern is
removed from the die & the
time
it is invested.

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 Wax Technique

A) DIRECT B) INDIRECT

Wax pattern is made Wax pattern is made on

directly inside the the
mouth, as in inlay die.
case.

Type-1 medium wax. Type -2 soft wax.

Exceptionally More commonly used

demanding procedure. technique.

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Sprue & Sprue former

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Sprue
Part of casting that acts as a channel for the
molten metal to flow into the mold cavity after
the wax has been eliminated.
PURPOSE:
To form a mount for the wax pattern & fix the
pattern in space so a mold can be made.
To create a channel for elimination of wax
during burn out.
To form channel for ingress of molten alloy .
To compensate for alloy shrinkage during
solidification.

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Wax pattern attached to the crucible former
with a sprue ready for investing. A ring liner is
in place.

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Spruing of wax pattern :

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FUNCTION:

Facilitate flow of molten metal from crucible

to mold.
Store additional metal & prevent shrinkage
porosity.
May be used as handle to remove wax
pattern.

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 Direct

Types of Sprue

Indirect

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 TYPES Shapes of
OF Sprue
SPRUE
Hollow,
Metallic Non Solid Round,
-Stainless Metallic Triangular
Steel, ,Wax,
-Steel, Resins,
-Brass Plastics

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 TYPES OF SPRUE

SELF
PREFABRICATED
FABRICATED

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 Sprue

DIAMETER
LOCATION
LENGTH
ATTACHMENT
DIRECTION

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SPRUING TECHNIQUE
DIRECT : sprue former provides direct connection
between pattern area & the sprue base/crucible
former area.
A basic weakness of direct Spruing is the potential for
suck-back porosity at the junction of restoration and the
Sprue.

INDIRECT: connector/ reservior bar is positioned

between pattern & the crucible former.
Indirect Spruing offers advantages such as greater
reliability & predictability in casting plus enhanced control
of solidification shrinkage .The Connector bar is often
referred to as a reservoir .

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 Sprue former

The sprue is attached to a crucible former,

usually
made of rubber, which constitutes the
base of the
casting ring during investing.
May be metal , plastic or rubber
The exact shape of the crucible former
depends on the type of casting machine
used.
With most modern machines, the crucible
former is tall to allow use of a short sprue
and allow the pattern to be positioned
near the end of the casting ring.
also referred to as a sprue former

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 Crucible formers/ Sprue formers are
basically of 2 types---

a) Steep-sided cone: used with metal

when casted using centrifugal casting force.

b) Shallow cone: used to cast metal

using stream/air pressure

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RESERVOIR

Piece of wax attached to the sprue about 1mm away

from the pattern ,as a enlarged round mass or a
connector bar between the wax pattern sprue former.

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Importance :

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 SURFACE TREATMENT OF
COMPLETED WAX PATTERN

Before the wax pattern is invested, it

should be cleaned of any debris, grease,
oils and separating medium.

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44
Preparatory steps for investing
Secure wax pattern,
Cleaning the wax pattern of debris, grease or oil
by surfactants-
a) Pattern cleanser
b) Dil. synthetic detergent sol.
c) Debbublizer

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Debubblizer :
Citric acid
Sodium 2-phenylpropane-2-sulfonate
Propane-1,2-diol - also known as propylene
glycol

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 Casting ring & liner
The casting ring serves as a container for
the investment while it sets & restricts
setting expansion of the mold.

Metal casting
ring Ring liner

Sprue base or
Crucible former

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Casting Ring
They are available as-
1) Shapes - Round
- Oval
2) Complete rings
I) - Rigid
- Metal (stainless steel)
- Plastic

II) Flexible - Rubber

3) Split rings
I) metal
II) plastic
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Casting Ring Considerations :
1) The internal diameter of casting ring
should be 5-10mm greater than the widest
measurement of the pattern and about 6
mm higher.

2) For single crown/inlay - small rings as

used. Diameter - 32 mm

3) For large fixed partial denture 63mm

round/oval shaped casting ring are used
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 CASTING RING
LINERS

NON ASBESTOS
ASBESTOS LINERS
LINERS CELLULOSE PAPER
AL-SILICATE CERAMIC

Asbestos:- carcinogenic potential makes it a biohazard.

Functions of a liner
Affords greater normal expansion in the
investment
The absorbed water causes a semi hygroscopic
expansion
Thickness not less than 1mm
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Liner technique
A)DRY LINER TECHNIQUE - tacked in
position with sticky wax.
B)WET LINER TECHNIQUE - lining ring is
immersed in water & excess water is shaken
off.

The liner is cut to fit the inside diameter of

the casting ring with no overlap and 3mm
short of the top and bottom of the ring , this
serves to lock the investment within the ring
& equalize expansion.

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52
RINGLESS CASTING TECHNIQUE
With the use of higher-strength, phosphate-
bonded
investments, the ringless technique has become
quite popular.
The method uses a paper or plastic casting ring
and is designed to allow unrestricted expansion.

53
Crucible formers and cone-shaped plastic rings for a
ringless casting system.
The crucible former and plastic ring are removed
before wax elimination, leaving the invested wax
pattern.
The systems are designed to achieve expansion that
is unrestricted by a metal ring.

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 Investing
Process by which the sprued wax pattern is
embedded in a material called an investment.
OR
A ceramic material that is suitable for forming a
mould into which a metal or alloy is cast.

The operation of forming a mold is known as

INVESTING

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56
 While the wax pattern is air drying,
the appropriate amount of distilled
water (Gypsum Bonded
investments), colloidal silica special
liquid (Phosphate Bonded
investments) is dispensed.
Powder should be weighed before
mixing it with liquid.
The liquid is added to clean dry
mixing bowl, and the powder is
gradually added to the liquid using
care and caution to minimize air
entrapment.

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Paint off technique

Wet investment material

is gently painted over a
complex wax pattern by
the use of sable hair brush,
covering it completely .

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Poured into the ring thinly
from a height (20-30)cm at
a slight angle from
bottom to the top of a ring

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60
 Allow the investment to set
(45 60) min before
burnout procedure
commences

Place invested pattern in a

humidator if burnout process is
delayed.

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METHODS OF INVESTING:
A) HAND INVESTING
B) VACCUM INVESTING

Advantages of vacuum investing

The amount of Porosity in the investment is
reduced
The texture of cast surface is smoother with
better detail reproduction
The tensile strength is greatly increased

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Brush technique of investing

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Vaccum Investing

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When the investment has set,
the "skin" at the top of the ring
is trimmed off.
The rubber crucible former is
removed, and any loose particles
of investment are blown off.
The ring is then placed in the furnace
for the recommended burnout schedule

65
 BURN OUT
Elimination of the wax
pattern from the mold of set
investment is referred to as a
burnout.
Ring may be placed on a
raised object within the oven
to completely eliminate the
wax & form a cavity into
which the molten metal is
cast.
Oven is preheated to approx.
400 degree C for 20 mins.
Temperature raised slowly to
700 degree C for 30 mins.

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a) For gypsum investment.
500 degree c - hygroscopic expansion
tech.
700 degree c - thermal expansion
tech.
b) For phosphate investment 700 - 1030
degree c
c) Ethyl silicate bonded investment- 1090
degree c

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 The ring should be maintained long
enough at the maximum temperature
(heat soak) to minimize a sudden drop
in temperature upon removal from the
oven.
Such a drop could result in an incomplete
casting because of excessively rapid
solidification of the alloy as it enters the
mold.

68
 If materials used during the casting process didn't
shrink or expand, the size of the final cast
restoration would be the same as the original wax
pattern. The management of dimensional changes is
complex, but can be summarized by the equation:

wax shrinkage + metal shrinkage = wax

expansion + setting expansion +
hygroscopic expansion + thermal expansion
.
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Casting
Casting of an alloy into the mold space
uses 2 basic requirements:
A) Heat source to melt the alloy

B) Casting force to force molten alloy

into mold

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Casting force > surface tension of alloy
+ resistance offered by gas in the
mold
This can be done by use of following
different type of force-
Vacuum force
Air or Gas Pressure
Centrifugal force

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 Melting temp of pure gold 1063c
Melting temp of gold alloy-924-960c
Melting temp of base metal alloy-1155-1304c

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 A) Heat Source: Different types of materials
and method are used as heat source to melt
alloy. Two basic modes are by using
1) Torch flame
Gas air
Gas oxygen
Air acetylene
Oxygen acetylene.
hydrogen oxygen generator
2) Electricity
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 METHODS OF MELTING ALLOY
A)TORCH MELTING B) ELECTRIC MELTING
-For low -For higher temperature
temperature metals.
metals
-Mixture of electric resistance
natural/artificial melting, induction
gas, oxygen/tank melting.
gas oxyacetylene
Less faster than
electric heating
but more faster melts alloy faster,& can
than resistance be easily over heated
heating.

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Two type of torch tips:
1.Multi-orifice
2.Single-orifice

Zones of the blow torch flame:

Zone 1 - colorless zone /Non combustion zone
Zone 2 Combustion zone
Zone 3 Reducing zone
Zone 4 - oxidizing zone
75
Melting methods
Gas air torch: -Gas-air torch is used to
melt conventional noble metal alloys
(used for inlays, crown and bridge) whose
melting points less than 1000c

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Gas oxy torch:
Used to melt metal
ceramic alloys of higher temperature
up to 1200c
The tip of torch is available as
single orifice/multiorifice. The
oxygen pressure is adjusted to10-
15 psi.
The flame is directed onto metal
with the nozzle of the torch about
1.5 cm away from the metal.
Complete fluid should be obtained
within 30 second at which point
the metal is poured into the
mould.

77
Oxy acetylene torch :
The actual production of flame can be done by
adjusting the pressure and flow of individual gases .
commonly advised pressure for acetylene nozzle is
3.5 N/cm2 and oxygen nozzle 7-10 N/cm2
one part of acetylene + 2 and half part of oxygen
The best results are obtained when flame is used
with a distance of 10cm between the face of blow
torch nozzle and the base of crucible.
If distance is reduced to
- 7.5 mm -slight porosity
- 5 mm -increased porosity due to occluded H2
gas

78
 CRUCIBLES :
The Melting of alloy requires a crucible to act
as a platform on which the heat can be applied
to the metal. Quartz Carbon
Clay

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1. Clay - High noble & noble metal types

2. Carbon - High noble crown and bridge

alloys also for higher fusing gold-based
metal ceramic alloys.
3. Quartz - Higher fusing, gold based metal ceramic
alloy & palladium alloys.

4. Zirconia alumina -High fusing alloys of any type :

specially for alloys that have a high melting
temperature or are sensitive to carbon
contamination.(Alloys like High Pd,Pd - Ag ,Ni based
or Co based are included in this category)

80
 The crucibles used with noble metal alloys should
not be used for melting base metal alloy

Crucible should be discarded if it contains large

amount of oxides and contaminants from previous
metals
Sufficient mass of alloy must be present to sustain
adequate casting pressure---

6gm is typically adequate for premolar and

anterior casting
10gm is adequate for molar casting 81
Casting machines
Air pressure casting machine.
Torch melting /Centrifugal casting machine.
Electrical resistanceheated casting
machine.
Induction melting casting machine.
Vacuum or pressure assisted casting
machine.
Direct-current arc melting machine.
 Air Pressure casting machine
Alloy is melted in the hollow left by the crucible
former by torch flame and then air pressure is
applied through a piston.
Carbon dioxide, carbon monoxide or nitrogen gas
can be used.
Pressure of 10-15 psi is usually applied.
Vaccum casting machine
Vaccum is applied through the base beneath the casting
ring and the molten alloy can be drawn into the mold by
NEGATIVE PRESSURE. In this case, the material is sucked
upwards into the mold by a vacuum pump. The mold in an
inverted position from the usual casting process, is
lowered into the flask with the molten metal.
CENTRIFUGAL CASTING
MACHINE

This machine makes use of centrifugal force to thrust the liquid

metal into the mold.
Centrifugal casting is a method of casting parts having axial
symmetry. The method involves pouring molten metal into a
cylindrical mold spinning about its
axis of symmetry. The mold is kept rotating till the metal has
solidified.
Mold material like steels, Cast irons, Graphite may be used.
85
 Centrifugal casting is carried out as
follows:
The mold wall is coated by a refractory
ceramic coating
Starting rotation of the mold at a
predetermined speed.
Pouring a molten metal directly into the
mold
The mold is stopped after the casting has
solidified.
Extraction of the casting from the mold.

86
 Direct current arc melting machine
The alloy is vacuum
melted & cast by
pressure in an argon
atmosphere.
Direct current arc is
produced between 2
electrodes
Alloy & water cooled
tungsten electrode.
The temperature within
the arc exceeds 4000
c, the alloy melts
very quickly.
Disadvantage- alloy can
become overheated.
87
ELECTRICAL RESISTANCE HEATED CASTING
MACHINE

-There is automatic melting of metal in graphite

crucible .
-This is advantageous for
metal-ceramic
restoration in which
trace amount of base
metals are prevented from
oxidation from torch flame
from overheating.

88
 INDUCTION CASTING
MACHINE

Metal is melted by induction field that develops with in

the crucible surrounded by water cooled metal tubing.
Molten metal is forced in to mold by air pressure or
both.
89
Vacuum
or pressure- assisted
casting machine
Titanium & its alloys require
vacuum arc heating argon
pressure casting machines.
The melting point of
commercially pure titanium is
1671c.
In such high temperature ,
either a graphite or water
cooled copper crucible is
used.
To prevent absorption of gases
in its molten state, titanium is
cast in the protective
atmosphere of argon or in
vacuum.
90
DIVESTING

It refers to removal of casting from

the investment mold

91
Recovery of a casting from phosphate-bonded investment.
A, Trimming is done from the bottom end of the ring.
B, Investment is being pushed out of the casting ring.
C, The mold is broken open.
D, Investment is removed from the casting.
Care must be taken to avoid damaging the margin

92
93
Sandblasting :
The casting is held in a sandblasting
machine to clean the remaining
investment from its surface.

94
Cleaning the casting
After the casting has solidified the ring is
removed and quenched in water.This
leaves the cast metal in annealed
condition resulting in a porous, soft,
granular investment that is easily
removed .(Gold alloys)

Often the surface of casting appears dark

with oxides and tarnish, such a film can be
removed by process called pickling.

95
Pickling
Heating a discolored casting in an acid.
Mask the dark/tarnished appearance of adherent oxide.
Solution used-
1.(50%) dil HCL,
2. (50%) dil Sulphuric acid,
Others ultrasonic device.

96
 Disadvantages of hydrochloric acid :
It is a health hazard
Fumes from the acid are likely to corrode the clinic and
laboratory metal furniture

Dilute hydrochloric acid should not be used unless

necessary neutralizing solutions are immediately at hand
It causes irreversible tissue injury.

Ultrasonic pickling can be carried out while the

prostheses is sealed in a Teflon container
Best method of pickling- the casting is placed in a test
tube and acid is poured

97
After cleaning of casting :

98
Trimming & polishing :
The casting is trimmed , shaped and smoothen
with suitable burs or stones.
The sprue is sectioned off with a cutting disc.
White stone ,rubber wheels, rubber disks, and
fine grit are included in the finishing and polishing
agents

99
Inspection & finishing of casting
A) Inner surface ( which will be in contact with the
prepared surface of the tooth)should be carefully
examined under higher magnification & illumination for
any discrepancy.
B) Tiny air bubbles in the investment create very minute
nodules on the inner surface, which interfere with the
fitting of the casting.

100
C) Improper coating of inner surface of a narrow wax
pattern with investment material may result in entrapment
of large volume of air.
This will result in large nodule over the metal blocking the
whole inner surface.

101
 Referenes
Craigs 13th edition
Phillips SCIENCE OF DENTAL MATERIALS:
ANUSAVICE 10th edition &11th edition
Contemporary fixed prosthodontics
Rosenstiel & Fujimoto 4th edition
Materials used in dentistry- S. Mahalaxmi 1st
edition
Vimal sikri- Operative dentistry 3rd edition

102
THANK
YOU

103