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A Seminar by Dr.Narayan
INTRODUCTION
Phosphate bonded
700C to 1030C.
37C water bath expands wax pattern. Warm water entering the investment mold from top adds some hygroscopic expansion.
Standardized hygroscopic technique was developed for alloys with high gold content; the newer noble alloy may require slightly more expansion. This added expansion may be obtained by making 1 or more of following changes.
1.
2. 3.
Depend almost entirely on high-heat burnout to obtain the required expansion, while at the same time eliminating the wax pattern. Additional expansion:
Slight heating of gypsum investments on setting. Thus expanding the wax pattern.
Water entering from wet liner adds a small amount of hygroscopic expansion to the normal setting expansion.
Gypsum Investments
Smoothness.
Overall dimension of investment. Too rapid heating.
Cracking of investment (outside layer expands >center section). Radial cracks interior to outward. Casting with fins or spines.
Investment decomposition and alloy contamination is related to the chemical reaction between the residual carbon and sulfate binder.
Calcium sulfate does not decompose unless heated above 1000C. Reduction of calcium sulfate by carbon takes place rapidly above 700C.
This reaction occurs when gypsum investment are heated above 700C in presence of carbon. SO2 as a product of this reaction contaminates gold castings and makes them extremely brittle.
Sulfur contamination.
Rough surface on casting.
Few investments may be directly placed into furnace at final burnout temperature
Phosphate Investments
Expansion of the wax pattern. Setting expansion (because of liquid used). Thermal expansion
Phosphate investments much harder and stronger than gypsum investments. Burnout temperature range from 750C to 1030C. 315C rapid heating held at the upper temperatures for 30 mins.
2 stage heating:
Placed directly in furnace at top temperature. Held for 20-30 min. then cast
Casting Machines
In a separate crucible by a torch flame, and cast centrifugally. Electrically by a resistance heating or induction furnace. Centrifugally by motor or spring action. By induction heating. Centrifugally by motor or spring action. Vacuum arc melted. Cast by pressure in argon atmosphere.
Oxidizing zone.
At proper casting temperature the molten alloy is light orange and tend to spin or follow the flame. Alloy should be approx. 38C to 66C above liquidus temperature.
The casting should be made when proper temperature is reached No more 30 secs should be allowed to elapse between the time the ring is removed from the oven and the molten alloy is centrifuged into the the mold
When the alloy is molten,slide the crucible against the ring,sprinkle flux over the metal
Hold the casting arm so that the pin drops away Release the arm and rotate till it comes to rest
Minimize porosity To increase the fluidity of the metal Film of flux formed on surface of alloy prevents oxidation
Reducing fluxes: Reduce oxides the present to free metal and oxygen. Excellent in cleaning old alloy. Eg; 1.Powdered charcoal
Broken arm feature accelerates the initial rotational speed of the crucible and casting ring.
The pressure gradient from the tip of the casting to the bottom surface is quite, sharp and parabolic in form, reaching zero at the button surface.
Pressure gradient before solidification reaches 0.21 to 0.28MPa (30 to 40 psi) at the tip of casting. Greatest rate of heat transfer to the mold is at the high pressure end of the gradient (tip of the casting).
Current is passed through a resistance heating conductor, and automatic melting of the alloy occurs in a graphite or ceramic crucible. Advantages:
For metal ceramic prosthesis. Base metals in trace amounts that tend to oxidize on overheating. Crucible located flush against casting ring.
Alloy is melted by induction field that develops within a crucible surrounded by water cooled metal tubing.
The electrical induction furnace is a transformer in which an alternating current flows through the primary winding coil and generates a variable magnetic field in the location of the alloy to be melted in crucible. Once the alloy reaches casting temperature in air/vacuum it is forced into mold by centrifugal force by air pressure, or by vacuum. More commonly used for melting base metal alloys.
Direct current arc is produced between two electrodes- the alloy and water cooled tungsten electrode.
The temperature between the arc exceeds 4000C. Has high risk of overheating.
Molten alloy is heated to casting temperature drawn into the evacuated mold by gravity or vacuum and subjected to additional pressure to force the alloy into the mold.
Used for titanium and titanium alloys. Under vacuum arc heated-argon pressure casting machine.
Casting Crucibles
Clay.
Carbon. Quartz. Zirconia-alumina.
Quenching: ring is removed and quenched in water as soon as the button exhibits a dull red glow Purpose of quenching
All the intermediate phases are changed to a disorderly state and ductility is increased Soft granular investment that is easily removed
Casting is held in an sand blasting machine to clean the investment from the surface. The blasting materials used are:
Pickling
Removal of oxide residues of carbon by heating the discoloured casting in an acid Advantages of HCl:
Disadvantages:
Method of cleaning
Place the casting in test tube or dish and pour acid over it
Other methods: Heating the casting and then dropping into the pickling solution
Finishing and polishing : Brown or White AlO2 stones are used Cleaning : Using a hemostat, steam or clean framework
CASTING DEFECTS
Casting is defined as the act of forming an object in a mold. The object formed from this procedure is called a casting. Any impressions or irregularities that result in unsuccessful casting which interfere with the fit of the final restoration-basically classified into 4 categories
DISTORTION
SURFACE IRREGULARITIES
Casting pressure
Composition of investment Foreign bodies
POROSITY
SOLIDIFICATION DEFECTS
TRAPPED GASES
RESIDUAL AIR
Premature termination of flow of molten metal Sprue freezes before feeding complete to casting proper Retain heat because of bulk and heat center of ring
MICROPOROSITY
OCCURS BY SOLIDIFICATION SHRINKAGE IN FINE GRAIN CASTINGS OCCUR FROM RAPID SOLIDIFICATION IF MOLD /CASTING TEMPERATURE IS TOO LOW
SIMULTANEOUS NUCLEATION OF SOLID GRAINS AND GAS BUBBLES AT THE FIRST MOMENT THAT THE ALLOY FREEZES AT THE MOLD WALLS
RATE OF MOLTEN METAL THAT ENTERS THE MOLD
Large concave depressions Inability of air in mold to escape through the pores in the investment Proper burnout,adequate mold and casting temperature,high casting pressure,proper l/p ratio
INCOMPLETE CASTING
MOLTEN ALLOY PREVENTED FROM COMPLETELY FILLING MOLD Insufficient venting and high viscosity
INCOMPLETE CASTING
CONCLUSION
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