 Casting Defects

 Finishing And Polishing Of The Casting

 An unsuccessful casting results in considerable trouble and
loss of time.

 In almost all instances, defects in castings can be avoided by

strict observance of procedures governed by certain
fundamental rules and principles.

 Seldom is a defect in a casting attributable to other factors than

the carelessness or ignorance of the operator.
1. DISTORTION

2. SURFACE ROUGHNESS & IRREGULARITIES

3. POROSITY

4. DISCOLOURATION

5. INCOMPLETE CASTING OR MISSING DETAIL

Distortion:
Causes-

• Distortion of wax pattern

• Due to uneven movement of the walls of wax pattern when

investment is setting. The gingival margins are forced apart by
the mold expansion, whereas the solid occlusal bar of wax
resists expansion during the early stage of setting.

Solutions-

• Proper manipulation of wax & handling of the pattern.

 Poor Surface Finish
Causes-
• Air bubbles on the pattern
• Water films causing ridges & veins on the surface.
• Too rapid heating resulting in fins or spines
• Underheating causing incomplete elimination of wax
• Inappropriate w/p ratio
• Prolonged heating
• Temperature of alloy too high
• Casting pressure too high
• Foreign bodies
• Impact of molten alloy
• Pattern position
Solutions-

• Use of Vacuum Investing Technique

• Vibrate before & after mixing

• Use a wetting agent to reduce surface tension of wax pattern.

• Air dry the wetting agent as excess water will dilute

investment, causing irregularities

• The mold should be heated gradually

• Heat the ring for sufficient period of time so that the

carbonaceous residue is removed

• Water/powder ratio should be accurate

• Gypsum bonded investments should never be heated above

700˚C

• Alloys submitted to vacuum casting showed decreased surface

roughness, compared to alloys submitted to acetylene- oxygen

flame casting.
 Porosity
Porosity of the casting can be spread within the casting and on

its surface. The surface porosity adds to surface roughness, but

can also be a sign of the internal porosity. The internal

porosity could weaken the casting, may cause discoloration if

spread to the surface and in extreme cases could lead to a

leakage.
 Porosities

Solidification
Trapped gases Residual Air
Defects

Localized Pinhole Gas

Microporosity
Shrinkage Porosity Inclusions

Subsurface
Porosity
 Localized Shrinkage Porosity
Causes:
 Generally caused by incomplete feeding of molten metal
during solidification.

 If the sprue is not properly designed and implemented then it

may solidify before the feeding is complete thus preventing a
continuous supply of molten alloy.

 This type of defect usually occurs close to the sprue-casting

junction.
HOT SPOT:-
Localized shrinkage porosity may result from the formation of HOT
SPOT when metal impinges on the mold surface so that here the
metal remains molten while it solidifies everywhere else. This hot
spot causes the local region to freeze last and result in SUCK BACK
POROSITY
Solutions:

 Flare the point of sprue attachment

 Proper placement of sprue

 Do not use excessively long sprue

 Use a reservoir

 Reduce the mold-melt temperature differential (i.e. lower the

casting temperature by about 30˚C).

Microporosity:

Caused by solidification shrinkage, but is generally present in

fine grain alloy casting when the solidification is too rapid for the
microvoids to segregate to the liquid pool. This is caused by the
mold or casting temperature being too low.
 Effect of Technical Factors on the Porosity Resulting
from Metal Solidification
Type Of Increased Increased Increased Melt Increased Mold
Porosity Sprue Sprue Length Temperature Temperature
Thickness

Localized Decreased Increased Decreased Decreased

Shrinkage
Porosity

Subsurface Increased Decreased Increased Increased

Porosity

Microporosity No Effect No Effect Decreased Decreased

 Trapped Gases
1. Pinhole Porosity
2. Gas Inclusion Porosity

• Both these porosities are related to the entrapment of gas

during solidification.
• Characterized by a spherical contour.
• Gas inclusion porosities are much
larger than pinhole porosities.
 Many metals dissolve or occlude gases while they are molten.

 On solidification , the absorbed gases are expelled and the

pinhole porosity results. (Formation of blebs and pores in the

metal)

 Large spherical porosities can be caused by gas occluded from

a poorly adjusted torch flame or the use of the mixing or

oxidizing zones of the flame.

SOLUTION:
 Can be minimized by premelting the gold alloy on a graphite

crucible or a graphite block if the alloy has been used before

 By correctly adjusting and positioning the torch flame during

melting.
 SUBSURFACE POROSITY
Cause-
This may be caused by simultaneous nucleation of solid grains
and gas bubbles at the first moment that the metal freezes at
the mold walls.

Solution-
• Diminished by controlling the rate at which the molten metal
enters the mold
 ENTRAPPED AIR POROSITY

• Referred to as Back Pressure porosity.

• Can produce large concave depression.
Causes-
Inability of the air in the mold to escape through the pores in
the investment or by the pressure gradient that displaces the
air pocket toward the end of the investment via the molten
sprue & button.
Solution-
• Proper burnout

• An adequate mold & casting temperature.

• A sufficiently high casting pressure

• Proper liquid : powder ratio.

• The thickness of investment between the tip of the pattern and

the end of the ring should not be greater than 6mm.

 INCOMPLETE CASTINGS

Causes-
• Inadequate spruing ( sprue former too small)
• Alloy not hot enough
• Incomplete elimination of wax residues from the mold
• Mold too cold
• Ingate obstructed
• Insufficient casting force
Solutions-
• Use proper size of sprue former

• Casting temperature should be higher than the

liquidus temperature of alloy

• Ensure that no debris blocks the ingate

• Use adequate amount of force for casting

 DISCOLOURATION
Causes-
• Sulphur contamination of casting causing black
castings
• Contamination with copper during pickling
• Contamination with mercury

Solution-
• Avoid overheating of investment
• Avoid use of torch flame as it contains sulphur
• Avoid use of steel tongs to hold casting during
pickling
• Castings should never be placed with amalgam dies
or kept on a table where amalgam scrap is present
Light microscope micrograph (100X)
•
Detected impurities and defects at same
•

micrograph, after computer processing for

of unetched Dentor S casting (A).
percentage porosity analysis (B)
SEM micrographs of grain boundaries in Dentor S casting
(A) and Midor S (B) casting.
 FINISHING THE CAST
RESTORATION
 A cast metal restoration is not ready for try-in and cementation

merely because it has been stripped of its investment.

 The unpolished surface is relatively rough and a series of

finishing procedures are needed to produce highly polished
axial surfaces.

 This will limit the accumulation and retention of plaque and

facilitate maintenance of health of the supporting periodontal
tissues.
Recommended sequence for finishing of a cast restoration. All procedures for
a zone should be completed before the next zone is started.
Zone 1 is the internal margin; Zone 2, the internal surface;
Zone 3, the sprue; Zone 4, the proximal contacts;
Zone 5, the occlusal surface; Zone 6, the axial walls; and
Zone 7, the external margins.
Abrasives for finishing. A sequence of progressively finer grades is used to attain the
desired surface. Carborundum disks and stones of varying degrees of coarseness (A)
are typically used first; these are followed by garnet paper and sandpaper disks (B),
rubber points and white Arkansas stones (C), and rubber wheels and points along
with small carbide burs for removing nodules (D)
 ZONE 1: INTERNAL MARGIN

Objective. To minimize any dissolution of the luting agent, a 1-

mm-wide band of metal must be obtained that is closely
adapted to the tooth surface.
 ZONE 2: INTERNAL SURFACE
(INTAGLIO)
Objective. No contact should exist between the die and the internal surface of
the casting. A uniform space of 25 to 35 um is necessary for the luting
agent to spread evenly. Any contact(s) must be identified and relieved by
careful selective grinding of the internal surface.
A, Internal surface of a casting. Note the
stone (arrow) adhering where the die
has been abraded by the casting.
B, A suitable marking agent (e.g., rouge
and chloroform) can be used to detect
areas that must be relieved to allow
complete seating.
When removing a nodule, remove slightly
more than the defect to ensure complete
seating of the restoration.
 ZONE 3: THE SPRUE
Objective. To reestablish proper coronal morphology and function, the
sprue must be sectioned, and the casting must be recontoured in the
area of its attachment.

•A, The button is most effectively removed by cutting around the sprue and then twisting it off.
B, With multiple castings made simultaneously, access is more difficult. When it is necessary to
sever a sprue completely, care must be taken not to damage the margin inadvertently. C and D,
Disks and stones are used for gross recontouring. E, The recontoured casting before finishing
 ZONE 4: PROXIMAL CONTACTS
Objective. The proximal contact areas are adjusted in the laboratory so that
they will be correct (or slightly too tight) when the casting is evaluated
in the mouth.

Rather than risk a deficient

proximal contact at evaluation, the
Cross sections showing properly finished
technician may reduce the cast
connectors
slightly by scraping the adjacent
teeth with a blade
Polishing connector areas. Twine impregnated with polishing compound
is an efficient way to polish this hard-to-reach area
 ZONE 5: OCCLUSAL SURFACE
Objective. Occlusal contacts are reestablished in static and dynamic
relationships to the opposing arch. Obtaining accurate and stable
contacts does not require highly polished metal occlusal surfaces. A
satin finish is acceptable. Occlusal morphology must ensure
positional stability and satisfy all functional requirements.

After complete seating is verified, the

initial point of contact is marked.
Occlusal prematurities are generally the
A, Occlusal adjustment is readily
result of excessively heavy contact on
accomplished with a pointed diamond or
the wax pattern
carbide. B, The grooves and fissures are
concurrently refined
 ZONE 6: AXIAL WALLS
Objective. When axial wall finishing is completed, the walls
should be smoothly contoured and highly polished, enabling
the patient to carry out optimum plaque control.
Finishing armamentarium. A, Assorted abrasives, sandpaper disks, rubber points,
and polishing wheels. B, Instruments used range from small carbides (for removing
nodules) and a steel wire brush (for occlusal surface smoothing) to buffing wheels
and compounds. C, A coarse wheel is used to true and thin the edge of a rubber
wheel. D, Buffing compounds applied on a felt wheel or bristle brush.
Finishing and polishing. A,
Initially a wire brush is used on
the occlusal surfaces. B, A fine-
grit sandpaper disk is applied
for removing pits and
irregularities from the axial
walls. Note that the margin is
not touched at this time. C and
D, Rubber points and small
carbides for selective finishing
of the occlusal morphology. E,
A rubber wheel is then used on
the axial walls. F, Castings,
after polishing with buffing
compound, immediately before
clinical evaluation. G, When
the fit has been verified
clinically, the margins are
polished. H and I, The
completed castings immediately
before cementation. J, Scanning
electron micrograph of a gold
alloy in the "as-cast" state.
 ZONE 7: EXTERNAL MARGINS
Objective. Margin finishing is critical to a restoration's longevity and
therefore deserves special attention. The objective of all cast
restoration finishing is a highly polished metal surface without
ledges or steps as the transition is made from restoration to
unprepared tooth. Failure to accomplish this will compromise
plaque control.

When subgingival margins

do not allow access, final
finishing is performed on the
die. During final polishing,
the margin is carefully
supported with a finger.
 PROCEDURE
► Cut the sprues from the casting with a separating disk.
► Grind off the sprue stumps with a 7/8 inch (21.7 cm) stone.
► Using a disk, barrel-shaped mounted stone, fine-tapered
mounted stone or carbide bur, depending on the access to the
area, remove the flash from the clasp arms, minor connectors,
rests, indirect retainers and denture base retention areas.
► Use larger wheels or stones to smooth the contour of the major
connectors and to remove small pits or defects.
► Smooth the rest of the framework except for those areas which
come in contact with the teeth such as the undersurface of occlusal
rests, the minor connectors, and the inner surface of the clasp arms
with a fine tapered mounted stone.
► Use an inverted cone stone or a separating disk to refine the
undercut butt joint of the finish lines, both internally and
externally.
► Optionally a series of sandpaper disks of decreasing grit can be
used to smooth all clasp arms and occlusal rests of castings
made of gold.
Rubber abrasive wheels, knife-edge wheels, disks and
points are preferred for fine finishing on the castings.
► Finish the metal surfaces that contact the teeth next. (inner surfaces
of the clasp arms, occlusal rests, indirect retainers and minor connectors.
Change these surfaces as little as possible since they must fit the teeth
accurately.)
► Smooth the entire remaining framework, except the clasp arms,
using the rubber wheels and points. When possible use the rubber
wheel by running it parallel to the length of the major connector,
not across its width. This will produce a smooth surface with less
waves. The knife-edge wheels may be used to smooth finish lines.
► Use small felt wheels with tripoli next to remove traces of marks
left by the rubber wheels and points on some of the more difficult
to rerach areas.
► The entire framework including the outer surfaces of the clasps is
polished with a small tripoli-impregnated cloth wheels.
► Polish the clasp arms with the cloth wheel running parallel to the
length of the clasp from the shoulder to the tip.
► After the casting has been thoroughly polished with tripoli, scrub
the casting with soap, water and a brush. In some of the difficult to
reach areas, use chloroform on a pledget of cotton to remove
traces of tripoli.
► Heat treat the casting following the manufacturer’s directions
because different alloys are heat treated in various ways.
► After the heat treatment, it will be necessary to pickle and repolish
the casting with tripoli. Scrub it to remove the tripoli.
► Polish the framework with a cloth wheel and rouge.
► Scrub the casting with soap and water or tincture of green soap
and ammonia and if necessary, chloroform to remove all traces of
the rouge.
► Dry the casting thoroughly with compressed air and examine it
carefully under a bright light and magnification for any scratches
or defects. (if any, repolish.)
 If the polish is satisfactory, the framework may now be tried
on the master cast or duplicate master cast.
 Problem Probable Cause Solution
-Sequence of finishing steps not -Follow steps as outlined; do
Polished surface is followed not “jump” steps
dull with -Steps not carried to completion -Complete each step before
Fine scratches before proceeding to next step proceeding to next one
-Casting too thin as a result of -Use correct gauge of wax
Major or minor incorrect wax-up during wax-up
connector over -framework overthinned with -check frequently during
thinned and flexible abrasive stones finishing
-Clasp was miscast -Use correct wax thickness
Clasp is nicked or -Clasp was nicked with stone or bur -take care to avoid nicking
notched during finishing framework with bur or wheel
Framework caught in lathe during Take care when using lathe
finishing to prevent framework from
Framework distorted being caught in polishing
wheel