DENTAL CASTING PROCEDURES

• HISTORY

• WAX PATTERN

• INLAY WAX

• SPRUE FORMER

• INVESTMENTS

• DIE MATERIALS

• WAX ELIMINATION
DEFINITION

Provides a metallic replacement for the missing

tooth structure with as much of precision as
possible.
HISTORY
1897 D. Phil Brook
1907 William Taggart
Lane - compensation for shrinkage
1932 Schen - hygroscopic expansion
1942 Sonder - lining of casting ring
ADVANTAGES
• Strength

• Reproduction of details

• Less corrosion & tarnish

• Less internal tarnish

• Finishing & polishing outside oral cavity

DISADVANTAGES
 Extensive tooth preparation

 Microleakage

 Galvanism

 Multiple visits

 Technique sensitivity
INDICATIONS
 Extensive tooth involvement

 Contact & contour replacement

 Occlusal correction

 Restoration of endo treated tooth

 Partially subgingival restorations

CONTRAINDICATIONS

 Young teeth with large pulp chamber

 Caries & plaque indices high

 Severe occlusal disharmony

 Dissimilar metallic restorations

WAXES
DENTAL WAXES

PATTERN PROCESSING IMPRESSION

INLAY BOXING CORRECTIVE

CASTING UTILITY BITE
BASE PLATE STICKY
 Mineral
Natural waxes Plant
Insect

Polyethylene
Polyoxyethylene
Synthetic Halogenated carbon wax
Hydrogenated wax
Wax ester
INLAY CASTING WAX

Inlay wax is a specialized dental wax that can be

applied to dies to form direct or indirect patterns for
the lost wax technique used for casting metal or hot
pressing of ceramics.

Generally produced in deep blue, green or purple

color.
COMPOSITION OF INLAY WAX
Paraffin-60%
Carnauba-20%
Ceresin-5%
Beeswax-5%
Natural resins(gum dammer)-less than 1%
Organic fillers- added to avoid excessive shrinkage,expansion due
to temp change
Microcrystalline wax- In minute amount.
Candelilla
Coloring agents
PARAFFIN WAX (MINERAL
WAX)
Generally the main ingredient of inlay waxes.
Obtained from high boiling fractions of petroleum(methane
series)
Mixture of hydrocarbons
Melting range 40-71o C. increases with increasing molecular wt.
Paraffin waxes have less than 0.5% oil.
Presence of oil lowers melting temp.
Likely to flake when trimmed.
Does not present smooth, glossy surface
Consequently other waxes and natural resins
are added.
CARNAUBA WAX (PLANT WAX)
• Derived from tropical palms
• It is quite hard, melting range 84-910C
• Combined with paraffin to-
Decrease flow at mouth temp
increase the hardness
• It contributes to glossiness of the wax surface
(Addition of 10 % carnauba wax to paraffin wax with a melting range of 20 0C
will increase the melting range to 460C.)
NATURAL RESIN (GUM DAMMER)

• Less than 1%
• Added to paraffin to improve its smoothness in molding
• It renders it more resistant to cracking and flaking
• Increases the toughness of the wax and enhances the smoothness and
lusture of the wax.
• Similar to paraffin waxes, but obtained from heavier oil fractions.
• It has a higher melting range 60-91 C0

• It is tougher and more flexible than paraffin

• It has less volumetric shrinkage during solidification than paraffin.
Decreases flow at moth temp.

Decreases brittleness of the wax at mouth temp.

CANDELILLA WAX (PLANT WAX)

• Same qualities as carnauba wax

• Added to paraffin to partially or entirely replace carnauba wax.

• Its melting point is lower, and it is not as hard as carnauba wax.

CLASSIFICATION OF INLAY WAXES
According to ADA SPECIFICATION 4

TYPE 1 -medium wax used for direct wax pattern

TYPE 2 - soft wax used for indirected wax pattern

 Cervical wax- for the cervical area, no shrinkage , a
Very accurate fit will be obtained, melting point 740C

Special wax for electrical wax heating unit(vario therm),dark blue-hard and light blue
soft are for modelling,trimming and dipping application, lilac-medium hard , red stress
Free for cervical margins, green-hard for trimming. Dip application yellow wax caps of
Uniform strength.
TYPES
Hard

Flow Regular/medium

Soft
IDEAL PROPERTIES

 Should soften uniformly & show colour contrast

 Should allow smooth carving without flaking

 Should be rigid and stable after taking the pattern

 Should not leave a residue more than 0.1 % at

500 ° C
FLOW

THERMAL PROPERTIES

WAX DISTORTION /WARPAGE OF WAX PATTERN

• MOST SERIOUS PROBLEM

• THERMAL CHANGES & RELAXATION OF STRESSES

• ELASTIC MEMORY
Distortion results from

-thermal changes
-relaxation of stresses (on cooling)
-occluded air
-molding
-carving
-removal and the time and temp of storage
MANIPULATION OF INLAY WAX

• Dry heat is preferred to the use of water bath (54-600C)

• For type I (direct technique), it is softened over a flame until it becomes
shiny.
• It is kneaded, shaped and pressed in the prepared cavity.
• Pressure is applied by finger or pt biting on it.
• It is cooled gradually, before taking out.
For fabricating indirect pattern (type II) die should be lubricated, preferably
with a lubricant, containing a wetting agent.
Excess must be avoided .
Melted wax is added in layers with a spatula or waxing instrument or may
be painted on with a brush.
Wax is then carved to proper contour.
A silk or fine cloth may be used, for final polishing.
WAX PATTERN

With matrix band

Without matrix band

Indication

• In easy accessible areas

• when cavity is small with minimal proximal extension.
• when cavity walls are flat ,line angles definite

Advantages

• The pattern is carved on tooth and not on model

• Little laboratory work compared to indirect tech
Disadvantages

• Great skill and patience is required to carve pattern in mouth

• When it is carved in indirect vision it is difficult and fatigue
• Discrepancies of the pattern at the gingival margin are difficult to detect
until the pattern has been carved and withdrawn
• as most of the adjustment and polishing is do on the tooth valuable chair
side time is lost
• If the casting fails ,the patient has to be recalled
 INDICATIONS
 Inaccessible areas
 Mostly full crowns and fixed partial dentures

 ADVANTAGES
 Easily made in inaccessible areas
 Less strain to patients and dental surgeon
 Newer impression materials give finer details
 Direct vision is used in pattern fabrication
 All margins better finished and burnished before cementation
 Inlay is made on articulated models – better occlusal restoration
 Polishing is done outside the oral cavity
 If casting failure occurs, patient recall not necessary
DISADVANTAGES

 Impression may be distorted

 Dentist depend on technician
WAX PATTERN
 SPRUE FORMER
Channel for flow of molten metal in to mold space

Size between 6 & 18 gauge ( 4 . 1 to 2 mm diameter )

Length 6 mm from the open end of the ring ( 1 / 4 inch )

Attachment 45 degrees and flared

 WAXING UP

The end of the sprue that is

attached to the wax pattern
should be waxed out to form
a gentle taper
CRUCIBLE FORMER

 Attached to the sprue

 Made of plastic, wax or ceramic
 Should not be too conical to allow very rapid
flow of the molten metal

Velocity of molten metal depends on:

• Density of molten metal
• Speed of evacuation of gases
• Viscosity of molten metal
• Length of sprue
• Flare of the sprue
INVESTMENTS FOR CASTING

INVESTMENT
a ceramic material that is suitable for
forming a mould into which a metal or
alloy can be cast
Procedure

INVESTING
¶ Strong to bear casting pressure

¶ Withstand high temperature

¶ Should expand enough

¶ Porous enough to allow venting of gases

¶ Have a smooth surface finish

¶ Should easily break away after casting

¶ Manipulation should be easy

¶ Should be in expensive
COMPOSITION

Refractory material - Withstands heat - Silica

Binder Ca SO 4 Alfa hemi hydrate , PO 4 and

Ethyl Silicates also serve the purpose .

Additives NaCl , Boric Acid , KSO 4, Graphite ,

Cu powder , Mg Oxide and
coloring agents.
 Gypsum bonded
Low melting
Gold alloys

Silica bonded Phosphate bonded

High melting High melting
Base metal casting Metal ceramics
GYPSUM BONDED INVESTMENT

Binder
Alfa hemihydrate of gypsum – 25 – 45 %
200 – 400 ° C - shrinks
Close to 700 ° C - expands
Above 700 ° C - decomposition

Silica
Modifiers:
Colouring agents
Reducing agents
Boric acid
Sodium chloride
QUARTZ

Alfa – low temp.

Two stable
polymeric forms

Beta – high temp.

Transition temperature 573 ° C

( Alfa form to Beta form )
Expansion 1.4 % at apprly. 573 ° C
 CRYSTOBOLITE

Uniform till 200° C after which a sudden expansion

from 0.5 –1.2 %
Above 250° C becomes uniform – 1.6 %
Transition temp. 220° C
ADA Spec no 2 ----investment for dental gold alloys.

TYPE-1
TYPE-2
TYPE-3
NORMAL SETTING EXPANSION
HYGROSCOPIC EXPANSION
A lenier expansion of the investment when
It sets in contact with water.

æ Casting ring in water bath

æ Controlled water added technique

æ Wet liner
THERMAL EXPANSION
PHOSPHATE BONDED INVESTMENT
ETHYL SILICATE BONDED INVESTMENT
DEFINITION -
A die is working replica of a single tooth, several teeth.
MATERIALS USED FOR FABRICATION OF DIES

 GYPSUM
 METAL
 POLYMER
 CEMENTS
 CERAMIC
1. It should be accurate
2. It should be dimensionally stable under normal conditions of use and
storage
3. Setting expansion and contraction, variations in response to change in
temperature need to be minimum
4.It should reproduce the fine details such as prepared and unprepared
tooth satisfactorily .

5.It should be strong and durable and be able to withstand the

subsequent manipulative procedures without abrasion or fracture.
6. They should withstand the carving and finishing procedures
7. The color should contrast that of the wax to ease the manipulation
8. Economical
9. Easy to use
GYPSUM
ELECTROFORMED DIES
Silver plating bath Copper plating bath

Ag Cyanide 36 gms Cu SO4 225 - 250

K Cyanide 60 Con H2 SO4 75 ml
K CO3 40 Phenol 10 ml
Distilled water Ethyl alcohol 25 -- 50 ml
A reservoir is added to prevent
"LOCALISED SHRINKAGE POROSITY"

The reservoir, should be larger

Wax is added around the sprue former 1-

2mm from

The pattern in order to create the reservoir.

CASTING RING

• usually metal
• - Use of paper or plastic casting ring.
• - Casting rings are available in different sizes.

• Selection of the casting ring

• For hygroscopic technique-Rubber ring
Thermal expansion - Metal ring
INVESTED CASTING RING

 Non corrodable & hard

 Thermal expansion similar

to that of the investment

 Should also be compatible with liner ,

 investment
the liner

Length 38 mm
Diameter 29 mm
CASTING RING LINER
ABESTOS LINER, FLEXIBLE RUBBERLINER, ALUMINO SILICATE LINER ,CELLULOSE
PAPER LINER

Semi hygroscopic expansion

Two layers- greater expansion

Shouldn’t be les than 1 mm

Length - Controversy

3.25 mm short of the end of the ring – more uniform expansion

RING WITH PATTERN
INVESTING

Process of covering or enveloping fully or part of a

wax pattern with an investment material.

Objectives:

Make surface of mould smooth

Allow venting of gas
Compensation of shrinkage
INVESTING

Vibrator 30 seconds
Hand investing Vacuum investing
Mixing 1 minute
INVESTING
BURNOUT PROCEDURE

 It’s the elimination of the wax pattern from the mold of

set investment material.

 Should be started after the investment has set

(preferably 45 – 60 mins) but ideally before 60 mins.

 If burnout is to be delayed the invested pattern should

be placed in a humidor at 100% humidity
Procedure:

The crucible former and any metal sprue former are carefully removed.

Any debris from the ingate area is cleaned with a brush.

Invested rings are placed in a room temperature furnace and heated to a

prescribed temperature.
 TECHNIQUES

Gypsum bonded invst. Phosphate Bonded invst.

Gypsum bonded investment

Hygroscopic low heat technique High heat thermal expansion technique

@500 @700

(Type II gypsum bonded (Type I gypsum bonded investment

Investment material) material)

Phosphate Bonded investment

@ 700-1300 C, depending on the alloy selected

 HYGROSCOPIC LOW HEAT TECHNIQUE

With type II gypsum bonded investment

Advantages
Less investment degradation
smoother castings.
Molds can be directly placed in the 500C furnace.

Disadvantages

High chances of back pressure porosity in this technique because retained fine carbon may
block the pores in the investment causing reduced venting

Also, the investments used for this technique are denser.

1. Warm water bath

2. Hygroscopic expansion [ 1.2 %– 2.2% ]

3. Thermal expansion [ 0% - .6% ]

Mold should remain in the furnace for 60 min

MODIFICATIONS NEWER NOBLE ALLOYS

1.  water bath temp to 40C.

2.  the burnout temp range 600C - 650C

3. Two layers of liner

to compensate for increased expansion requirement of noble alloys

CONTROLLED WATER ADDED TECHNIQUE

Hygroscopic expansion is directly proportional to the amount of water added

Soft flexible rubber ring is used

Specified amount water added according to requirment

Rarely used
 HIGH – HEAT THERMAL EXPANSION
TECHNIQUE

Type I gypsum bonded investments

Compensation expansion

1. Heating the gypsum investment on setting(1 – 1.6% )

2. Water entering from the wet liner (hygroscopic expansion)
3 Expansion of wax pattrern

Require use of metal ring for protection

Moulds placed in furnace @ room temp.

Slowly heated to 650C - 700C in 60 mins.

Held for 15 – 30 mins at the upper temperature.

CASTING MACHINES

Air pressure casting

Centrifugal casting

Vacum casting

[ ceramic casting with piston plunger ]

AIR PRESSURE CASTING

Old method of casting

Pressure 10 to 15 p s i

Solidification of the metal in 5 seconds

CENTRIFUGAL CASTING

Spring loaded Pressure 30 to 40 p s I

Spring is 5 winds or 3 winds

11 gauge sprue 5 winds 0 . 38 minute

3 winds 0 . 46
14 gauge 5 0 . 44
3 0 . 54
17 gauge 5 0 . 51
3 0 . 67
CENTRIFUGAL CASTING

C F is directly proportional to the square of the

speed in revolutions per second

C F varies directly with the radius of the path

C F is directly proportional to the weight

of the metal

[ C F Centrifugal Force ]
INDUCTION CASTING
CASTING FLAME

Blow torch with

oxygen gas and Flame has 4 zones
multi orifice tip cool mixing zone ( combustion free zone )
Torch flame should partial combustion ( green )
not be more than reducing zone ( dimly blue , hottest )
40 mm oxidizing zone less heat
combustion occurs with air
metals can form oxides
and contaminate metal

BURNERS & FLAMES

FLUXES

Borax

Reducing Fluxes - Borax + Carbon

Fluxes dissolve the oxides formed

during melting of alloy
MELTING OF ALLOY

MELTED ALLOY
MOLD SPACE FILLING

Density of cast metal

Porosity of investment

Length & diameter of sprue

Angulation of sprue

No of sprue
MELTING OF ALLOY

1. Blow torch
a, Natural Gas
b, Natural Gas and oxygen
c, Oxyacetylene & oxygen mixture

2. Induction Energy
RECOVERY OF CASTING

• Leave in the casting machine for 12 min.

• Quench in water

HEAT SOFTENING

• Improves softness and ductility of the alloy

• Better finish
Pickling

Hydrochloric acid

Produces lot of fumes corrosion

Sulphuric acid + Potassium dichromate preferable

CASTING FAULTS

A casting may be:

1. Dimensionally inaccurate

2. Have a rough surface and/or fins

3. Be porous, contaminated or incomplete

(The Clinical Handling of Dental Materials. BGN Smith, PS Wright, D

Brown)
DEFECTS OF CASTING

DISTORTION

SURFACE ROUGHNESS AND IRREGULARITIES

POROSITIES

INCOMPLETE CASTING
SURFACE CRACKS
DISTORTION

Wax pattern

T E , S E , H E of investments

Improper handling of wax pattern

Use of wax not conforming to ADAS # 4

SURFACE ROUGHNESS

Finely spaced irregularities having a definite pattern

Irregularities without definite pattern - Ridges & veins

Due to improper wetting, trapping of air bubble

Overheating of the alloy

INCOMPLETE CASTING

Inadequate sprue

Mold too cold

Ingate expected

Insufficient pressure to force the molten metal

Inadequate quantity of molten metal

Alloy not fully melted

ROUNDED MARGINS

 Incomplete burn out resulting in Carbon residue in mold space

 Proper burn out can reduce the effect

 Insufficient sprue diameter & length causes freezing of metal ahead of the
mold
DISCOLORED CASTING

Sulphur contamination heat over 700 ° c

Copper contamination if steel tongs are used during pickling

Mercury contamination if amalgam die is used

POROSITIES IN CASTINGS

Locallized shrinkage porosity

Hot spot

Reservoir, flaring of sprue , & reducing mold temperature by 30 to 50

degrees can prevent this type of porosity
POROSITIES CONTD

Micro porosities
Premature solidification , low casting temperature

Gas inclusion
Entrapment of air during solidification ( spherical voids )
Can also absorb oxygen & hydrogen ( poorly adjusted flame )

Back pressure porosity

Improper venting

Sub surface porosity

Simultaneous nucleation of solid grains and gas bubbles
Paraffin Hydrocarbon ,
MP 40 to 70° C
Flakes easily Ceresin Product of petroleum refining
11 to 15 % or lignite refining
contraction Increases the M.P. of paraffin

Micro crystalline wax Montan From lignites .

61 to 90° C tougher 72 - 92 ,
more flexible than paraffin Hard but brittle
Easily blend with any other wax

Ozokerite
USA & Western Europe
Ceresin - St. & br. Chain
Petroleum & lignite refining product
Increases M.P. of paraffin

Montan wax – L. refining

72 – 92 °C
Hard, brittle & lustrous
Blends with any wax

Ozokerite - only in Europe & USA

M.P. 65°C
Similar to high mol. Wt. Paraffin

Gums – g. tragacanth & g. arabic

Fats – esters of fatty acids with glycerol

Tasteless, colourless , odorless & clear

PLANT WAXES
Carnauba wax – Hard, brittle
M.P. 84 - 91 °C
Reduces flaking

Candelilla wax - Hardens & reduces flaking of paraffin

M. P. 68 - 75°C

Japan wax - Fat + glycerides of palmitic & stearic acid

Tough, malleable & sticky
M.P. 51 °C

Cocoa butter - Fat, glycerides, pal. & stearic, oleic &

lauric acids
INSECT & ANIMAL WAXES

Bees wax – Esters of myricyl palmitate & hydrocarbons

M. P. 63 – 70 °C
Brittle at room temp., plastic at body temp.
Modifies paraffin
Main ingredient in sticky wax

Sper macetti –From sperm whales

wax Wax ester
Used as a coating of dental floss
 INLAY WAX

ADA S # 4 ISO 1561

COMPOSITION:

Paraffin 60 %
Microcrystalline wax + ceresin 10 %
Carnauba + candililla 25 %
Bees wax 5 %

Deep blue, green, purple rods or sticks of

7.5 cm long & 0.64 cm in diameter