Casting of cobalt chromium alloys

Step By Step Operations Of Wax Melting & Centrifugal Casting

The Eight Main Steps 1. Original Pattern Making 2. Rubber Mould Making 3. Wax Pattern Making 4. Investing 5. Burnout 6. Casting 7. Cleaning 8. Finishing

S-U-WAX PATTERNS Assorted preformed wax patterns are produced from casting wax especially developed for this purpose. They are distinguished by their high flexibility and good adhesion. A new manufacturing process ensures their easy removal from the model. The working temperature should not fall below 68F (20C). Store in a cool place.

-U-FLEXIBLE WAX & S-U-HOLE RETENTION A casting wax in sheets for the production of Cr-Co castings. It is transparent, extremely flexible and stable and best worked at hand temperature. As it is self-adhesive, this wax is easy to adept, and maintains constant thickness even in prominent areas. Available with grained, veined or smooth surface.

Why?????
to design the removable partial denture framework complete a laboratory work authorization that communicates the desired design and authorizes its fabrication evaluate the quality of the framework

Duplicating a stone cast

To preserve the original master cast For fitting a removable partial denture framework without danger of fracture or altering the surface of the master cast For processing a temporary prosthesis where wax relief and blockout on original master cast can allow production of a duplicate cast , to allow for easier insertion. To allow formation of of an investment cast for framework fabrication.

 Purpose of Duplication - To produce two casts:

Refractory cast used for casting RPD frameworks
Heat resistant duplicate of a modified (blocked out and relieved) master cast Made from dental casting investment Acts as the base for forming the RPD framework in wax and plastic

Duplicate master cast used for seating RPD frameworks

PREPARING MASTER CASTS FOR DUPLICATION

Purpose of Blockout and Ledging
Blockout: To eliminate undercut areas on a cast with blockout material Ledging: To control the amount of undercut the clasp tip engages

Definition of partial denture relief The adaptation of wax to the edentulous areas of a cast, before duplication, to create a raised area on the refractory cast

Purpose of partial denture relief

Acrylic retention
Allows a space for acrylic to flow around the denture base retention

Internal finish lines

Establishes a definite junction for metal framework and acrylic resin Located on the tissue side of RPD Used as a guide for placement of external finish line

Relief of lingual bar and approach arms

Eliminates the possibility of tissue ulceration due to framework rubbing during function Lingual bars when used in conjunction with distal extension defects, usually require relief Relief is rarely, if ever, indicated under palatal connectors or toothborne RPDs

Equipment and Materials

Blockout wax must have the following physical properties:
Firm - must resist temperatures of at least 10F in excess of the pouring temperature of the duplicating material

Easy to carve Sheet casting wax

Supplied in various gauges Pressure sensitive - do not compress the wax upon application, it results in an uneven layer of relief Adhesive - one side is tacky to adapt to cast

Procedures for Blockout, Ledging and Relief Wax Adaptation

A) Blockout all undercuts
Cast remains on the survey table during the entire procedure Application of blockout wax and baseplate wax
Below the survey line around the teeth Below the survey line of soft tissue undercuts within the RPD design Blockout gross undercuts outside of framework area, e.g., (anterior labial)

Remove excess wax

Warm the blockout tool slightly Remove excess blockout wax from the appropriate areas by moving blockout tool around teeth and tissue Ensure there is no wax above the survey line

Procedures for Blockout, Ledging and Relief Wax Adaptation

B) Ledging
Locate desirable undercuts Expose the terminal 1/3 of the retentive clasp tip design from the blockout wax
Use a roach carver to trim the wax at a right angle (90) to the abutment tooth surface; do not scratch the cast Ledge should be free of debris

Procedures for Blockout, Ledging and Relief Wax Adaptation

C) Denture base retention relief
Select the proper gauge wax
Use 24 gauge adhesive wax unless directed otherwise The lower the gauge numbers, the thicker the wax

Adapt and cut the wax

Ensure the finish line is sharp and accurate
Cut wax at a 90 angle to the tissue Do not bevel or taper the edge

Cut the wax 1.5mm from the abutment teeth

Procedures for Blockout, Ledging and Relief Wax Adaptation

D) Cut the tissue stop
Purpose of the tissue stop

To hold the retention area of the framework off of the tissue while packing forces are being applied
Ensure the tissue stop is placed directly over the crest of the ridge preventing movement of the tissue stop in a lateral direction Cut 2mm by 2mm square

Preparation of the cast for duplication

On maxillary casts, check beadline
Beadline should be scribe into cast
1 mm wide and .5 mm deep Used only on maxillary design

Ensure it is void free Ensure it is free of wax and debris

Soak the master casts

Eliminates air from casts and replaces it with water so casts will not draw moisture from hydrocolloid and adhere to casts Methods of soaking the casts
On their heels or with teeth down In SDS (Saturated calcium sulfate dihydrate solution) water Allow to soak in warm hygrobath
90F for 30 mins before removing from water Casts made from improved stone require a much longer soaking time

MATERIALS USED FOR DUPLICATION

Hydrocolloid (agar type) Dupli-chrome - Reversible Red Strip investment Phosphate bound investment Contains crystobolite which facilitates expansion and enables the investment to withstand high heat Expansion factors: Molten metal shrinks 1.7% as it cools. This must be compensated by the expansion of the investment material Setting Expansion - 0.4% This occurs while the cast is setting up Hygroscopic Expansion - 0.3% Occurs as the investment sets- up in the hydrocolloid Thermal Expansion - 1.0% Occurs in the burn-out oven when the investment is subjected to high heat

Important Rules Always use distilled water when mixing investment Use the manufacturer's recommended water/powder ratio-more water/less expansion Be sure to roll the canister to mix all particles

Procedures
Autoduplicator: Used to breakdown and store hydrocolloid at a given temperature

Use manufacturers recommendations for temperature

Set low temp at 50 degrees Celsius Set high temp at 90 degrees Celsius Fill duplicator with hydrocolloid
Fill duplicator at least 1/2 full - material will burn if less than 1/2 full

Start breakdown cycle (cookdown)

Push cycle button on Temp will rise to high temp setting at 2 degrees per minute, then lower to low temp setting In 3 to 5 hours the hydrocolloid will be melted and cooled down to pouring temperature Clear the valve -Open the valve to drain off approximately 150 cc of hydrocolloid to clear the valve of lumps and debris Safety: Keep your fingers out of the unit when it is running. Use caution when pouring duplicating material, because it is hot

Select a duplicating flask that allows at least 12mm clearance around the cast Remove the cast from the water bath Check the relief wax to make sure it has not lifted off cast Blow off excess water from the cast (DO NOT USE AIR HOSE) Place cast in duplicating flask Position cast on center of base Place body on base, ensure it is completely closed Fill flask with hydrocolloid Center the flask under the valve Open the valve slowly until the stream of hydrocolloid is about the diameter of a pencil Fill flask completely Close valve

Cool the duplicating flask Place in cooling tray. Ensure water level does not extend higher than top of the base. Cast and base cool before the body. The hydrocolloid solidifies toward cast for more accurate duplication. Ensure the water remains below room temperature, but not less than 55 degrees F. The water should circulate in the tank. Length of cooling time Small flask - 30 minutes Large flask - 45 minutes

b.Pour the refractory cast 1.Water/powder ratio for redstripe investment a.For average size frameworks use 25cc distilled water to 200 grams investment b.For large horseshoe frameworks or cast metal bases uses 24cc distilled water to 200 grams investment 1.For very large areas of metal, more expansion is needed 2.Less water gives more expansion 2.Retrieve master cast from hydrocolloid a.Pry off base with a knife b.Clean off any hydrocolloid covering the bottom of the master cast c.Using 2 knives, place them against the cast d.Pry master cast out of hydrocolloid by giving cast a quick upward snap e.Make sure the relief wax is still on the cast 3.Mix water and investment Vacuum mix investment for 30 seconds

Fill the mold with investment Spot fill; do not flow the investment around the mold as is done for an alginate impression Hydrocolloid contains salts - filling impression like an alginate will distort the refractory cast Insert sprue former - too much pressure can distort the impression 7-8mm from the major connector design the sprue provides a channel for the escape of gases and debris during burnout procedure The sprue provides a channel for molten metal to enter the cavity of investment mold during casting procedure Top of sprue cone should be parallel with the occlusal plane Fill the mold to the top Investment will not have proper setting expansion if it contacts the metal flask Allow the investment to set for 20- 35 minutes

Recover refractory cast Always remove the hydrocolloid from the cast, never the reverse Cut the hydrocolloid in 4 areas Make cut at each cuspid area Make cut at each heel area Gently peel hydrocolloid away from refractory cast Remove sprue former Gently turn the sprue former until it comes loose from refractory cast Make every effort not to touch areas within the design on the cast

Prepare hydrocolloid for reuse Rinse hydrocolloid under running water Remove all particles of investment, modeling clay and wax Store hydrocolloid in an airtight container until it's ready for cookdown Replace the hydrocolloid after 200 duplications or as needed Prepare casts for dehydration Inspect for voids and bubbles in critical areas Inspect internal finish line for defects Smooth edge of sprue hole - eliminates the possibility of investment pick-up during the casting procedure Outline cast for trimming- make line approx. 6 mm away from extremities of design with a wax pencil Smooth base of refractory cast Trim heel area at 90 degree angle Trim the rest of cast at 45 degree angle Rinse off slurry

10.Purpose of Dehydration and Wax-dip a.Dehydration 1.Prepares the refractory cast for wax dipping by removing moisture 2.Preheat cast for wax dipping b.Wax dip 1.Assures a smooth dense cast necessary for waxing procedures 2.Eliminates soaking refractory casts prior to investing a.Unsealed casts would extract moisture from outer investment b.Refined Beeswax - used for wax dipping

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Dehydration and Wax-dip Dehydrating Oven Purpose: Used to dry refractory casts prior to sealing them with beeswax Safety: Take precautions for handling hot materials Beeswax heater Purpose: To melt refined beeswax and maintain the wax at a temperature between 280F and 300F Safety: Use carrier to immerse casts into the molten wax Do not drop casts into the molten wax, as splashing of hot wax can result in serious burns Avoid touching the exterior of the unit during and immediately after its operation Place refractory casts into dehydration oven at 180 degree - 200 degrees F for 1 hour Wax-dip in beeswax at 280 - 300 F Beeswax must be 100 degrees above dehydrating oven Place cast in hot wax using cast holder Cool casts after wax-dip Place wax-dipped casts on a paper towel on their heels Blow lightly on cast to prevent puddling

Wirosil duplicating flask with its stabilizing insert and three replaceable palate formers of different sizes ensure extremely low silicone consumption through flexible positioning.

Wirotop automatic mixing and metering unit ensures the two components are mixed to prevent formation of bubbles.

In Wiropress pressure compaction unit, duplicating silicone is forced into critical areas under pressure, thereby reducing number of bubbles.

After hardening under pressure, cast is detached by blowing compressed air between cast and mold.

Spraying with surfactant eliminates any reaction with investment material and ensures more accurate casting surface.

WAXING THE REMOVABLE PARTIAL DENTURE FRAMEWORK