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Fundamentals of
of Spruing,
Spruing,
Investing
Investing &
& Casting
Casting
PRESENTED BY:
Dr. Mubashir Rasheed
M.D.S (Student)
Operative Dentistry
SUPERVISOR:
Prof. Dr. Sohail Abbas Khan
Head of Operative Department
deMontmorency College of Dentistry
Fundamentals of Spruing, Investing &
Casting
Outline of Presentation
Spruing Technique
High Heat Casting Investments
Investing Technique
Melting & Casting Technique
Law Of Casting
Analyzing Casting Failures
The Sprue
Definition:
Its a channel through which molten
alloy can reach the mold in an invested
ring after the wax has been eliminated.
Role of a Sprue:
1.Create a channel to allow the molten
wax to escape from the mold.
2.Enable the molten alloy to flow into the
mold which was previously occupied by
the wax pattern.
*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
Sprue Former
*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
Sprue Materials
Significance
1. To avoid distorting thin areas of wax
during attachment to the pattern.
2. To permit smooth flow of the alloy.
Significance
Since the molten metal may abrade or
fracture investment in this area and may
result in a casting failure.
The entering metal impinges the mold
surface at this point (90-degree angle)
and creates hot-spot, producing a
localized lingering of molten metal after
the casting has solidified. Creates
shrinkage void, or suck-back porosity.
*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
Significance
Short Sprue Length:
The gases cannot be adequately
vented to permit the molten alloy to fill
the ring completely leading to Back
Pressure Porosity.
Long Sprue Length:
Fracture of investment, as mold will not
withstand the impact force of the
entering molten alloy.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
Sprue former
Diameter/Gauge
Sprue Former should be thicker than the
pattern to which it is attached.
Since the thin sections solidify and
contract first, they will draw molten metal
from thicker sections.
Diameter 8(3mm),10(2.5mm),12(2mm)
gauge
Sprue act as a ideal reservoir for these
sections.
*Laboratory Procedures for Full and Partial Dentures by Derek Stanananought
Fundamentals of Spruing, Investing &
Casting
Significance
Failure to cater for this may result in a
reduction in density of the casting by
the presence of voids called Porosity
Reservoirs
Round ball reservoir & a bar reservoir also
called connector
Fundamentals of Spruing, Investing &
Casting
Significance
Reservoir is the largest mass of any part
of the Sprue system & it is present in the
heat centre of the ring, it is the last part to
solidify.
These properties allow continuous feeding
of the molten alloy to compensate for
Solidification shrinkage & avoid Shrinkage
porosity.
*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
Spruing Techniques
1. Direct Spruing:
The flow of the molten metal is
straight(direct) from the casting crucible to
pattern area in the ring.
Even with the ball reservoir, the Spruing
method is still direct.
A basic weakness of direct Spruing is the
potential for suck-back porosity at the
junction of restoration and the Sprue .
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing &
Casting
Suck-back porosity
It can be seen at the junction of restoration and Sprue
2. Indirect Spruing:
Molten alloy does not flow directly from the
casting crucible into the pattern area, instead
the alloy takes a circuitous (indirect) route.
The connector (or runner) bar is often used to
which the wax pattern Sprue formers area
attached.
Indirect Spruing offers advantages such as
greater reliability & predictability in casting plus
enhanced control of solidification shrinkage
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing &
Casting
High-heat Casting
Investments
The high melting ranges of metal
ceramic alloys exceed the upper limits
of the Gypsum-bonded investments.
1.Phosphate-bonded casting Investments
2.Silica-bonded casting Investments
Phosphate-bonded Casting
Investments
Carbon-containing
Noncarbon-containing
Main Constituents of
phosphate-bonded
Investment
1. Binder:
Magnesium Oxide (basic) &
Mono- ammonium Phosphate (acid)
2. Filler: Silica (quartz/Cristabolite or mixture
of both)
Binder: It hold other ingredients together.
Provide rigidity.
Filler: Provides refractory during heating.
Regulate thermal expansion.
*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
Investment-Casting Alloy
Interaction
Variations can occur in the performance of
alloys with different investments (Barreto et al,1980;
Hinman et al,1985).
2.
Investing Technique
1. The wax pattern cleaned of any
debris, grease or oil.
Wax pattern cleaner or diluted
synthetic detergent.
Thin film of cleaner on pattern
reduces surface tension of wax
better wetting of investment.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
2.
Investment mixing
Hand mixing
Vacuum mixing
Advantages
Amount of porosity in the investment is reduced
Texture of the surface casting is smoother with
better detail reproduction
Compressive strength of investment is increased
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Choice of Fuels
Three fuel sources are used for Casting
Torch
1.Acetylene
2.Natural Gas
3.Propane
Zones of Flame
1. Zone in which air & gas are mixed
before combustion:
No heat is present in this zone.
2. Combustion zone:
Green, gas & air are in partial
combustion.
This zone is oxidizing & should always be
kept away from metal during fusion.
*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
3. Reducing zone:
Dimly blue, hottest part of the flame.
This area should be constantly on the metal
during fusion.
4. Oxidizing zone:
Outer most zone, here combustion occurs
with Oxygen in air.
Under no circumstances should this portion
be employed to fuse the alloy.
Low temperature, Causes oxidation of the
metal.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
Casting Machines
1. Air pressure casting machines
Alloy is melted in situ in crucible hollow of the
ring, followed by applied air pressure on the melt.
2. Centrifugal casting machine
Alloy is melted in a crucible, and forced in to mold
by centrifugal force.
3. Electrical Resistance/ Induction melting machine
Alloy is melted electrically by a resistance or
induction furnace, then cast into mold
centrifugally.
*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips
Cradle
Counter
weight
crucible
Base
Casting Crucible
Except for Air pressure casting
machine, all other units require a
crucible to hold the alloy before &
during melting procedure.
1.Clay Crucibles
2.Carbon Crucibles
3.Quartz Crucibles (zircon-alumina)
*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
Quenching in Water
Consider the gold crown & bridge alloys.
After casting has been completed, ring is
removed & quenched in water.
Advantages:
1.Noble metal is left in an annealed condition
for burnishing & Polishing.
2.When water contacts hot investment, violent
reaction ensues. Investment becomes soft,
granular & casting is more easily cleaned.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
Pickling
Surface of the casting appears dark
with oxides and tarnish. Such a surface
film can be removed by a process
called Pickling.
Best method for pickling is to place
a casting in a dish & pour acid over it.
Heat the acid but don't boil it.
*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips
Fundamentals of Spruing, Investing &
Casting
Hydrochloric acid
Sulfuric acid
Ultrasonic devices
Gold and palladium based metal
ceramic alloys and base metals, these
alloys are not generally pickled.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips
Penalties
Penalties for not obeying this law are:
Clod shuts
Short margins
Incomplete castings
Penalties
Penalties for not obeying this law are:
Cold shuts
Short margins
Penalties
The penalty for not obeying this law is:
Shrink-age porosity
Penalties
The penalty for not obeying this law are:
Shrink-age porosity
Suck-back porosity
Penalties
The penalties for not obeying this law
are:
Shrinkage porosity (and potential
Distortion during porcelain firing)
Suck-back porosity
Penalties
The penalties for not obeying this law are:
Voids in the casting ring
Surface pitting
Penalties
The penalties for not obeying this law
are:
Mold fracture
Casting fins
Shrinkage porosity
Penalties
The penalty for not obeying this law is:
Bubbles
On the surface of the casting as a result
of the entrapment of air (too little agent)
or excess liquid (too much wetting agent).
Penalties
The penalty for not obeying this law is:
Ill-fitting castings
Penalties
The penalties for not obeying this law are:
Small Nodules on the casting
Weak mold
Distortion of the casting
Penalties
The penalties for not obeying this law are:
Mold crackling/Blowout
Fins on the casting
Therefore, use at least a 30-minute heatsoaking at 800 *F for the first burnout stage.
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing &
Casting
Penalties
The penalties for not obeying this laws
are:
Cold Shuts
Short Margins
Cold Welds
Mold Cracks
Casting Fins
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing &
Casting
Penalties
The penalties for not obeying this law
are:
Cold Shuts
Short Margins
Cold Welds (too little heat)
Rough Castings
Investment Breakdown (too much heat)
*Introduction to Metal Ceramic Technology by W. Patrick Naylor
Fundamentals of Spruing, Investing &
Casting
Penalties
The penalties for not obeying this law are:
Gas porosity
Change in the alloys Coefficient of
thermal expansion (due to alloy
contamination)
Penalties
The penalties for not obeying this law
are:
Cold Shuts
Short Margins
Clod Welds (insufficient force)
Mold Fracture & Fins (too much force)
Penalties
The penalties for not obeying this law
are:
Cold shuts
Short margins
Incomplete castings
Penalties
The penalty for not obeying this law is:
Hot Tears in the restoration
Thank You!