CASTING

DEFECTS
 TOPICS INCLUDED IN
SEMINAR
Introduction
Classification of different types of defects
Etiology of casting defects
Its prevention
Conclusion
References
 Introduction
Casting procedure is technique sensitive procedure.
Proper sequence of all steps is essential for obtaining
correct casting.
If proper procedure is not followed, then casting may
have some defects. The casting in such cases may not fit
properly or it may have poor aesthetic & mechanical
properties.
 Classification Of Casting Defects
(Coombe)
◼ Distortion
◼ Surface Roughness

◼ Porosity

◼ Incomplete Casting

◼ Contamination of casting by

a) Sulphur compounds, formed by the breakdown of the

investment, when the ring is overheated
 Classification Of Casting Defects
(Coombe)

b) In addition, a casting can be contaminated due to :

Oxidation, caused by :
- Overheating the alloy
- Use of oxidizing zone of flame
- Failure to use flux
 Distortion

◼ Distortion of the casting is usually due to distortion of

wax pattern
Some distortion of wax occurs when the investment
hardens or due to hygroscopic setting expansion. It
does not cause serious problems
Some distortion of wax
occurs during manipulation,
because of the release of
internal stresses
 Distortion
◼ Minimize distortion by :

1. Manipulation of wax at high temperature

2. Investing pattern within one hour after

finishing

3. If storage is necessary, store in refrigerator

 Surface Roughness
◼ Surface roughness can usually be traced to :
1) Air bubbles on wax pattern cause nodules on the casting.

it can be avoided by :-
- Proper mixing of investment
- vibration of mix or by vacuum
investing
-Application of wetting agents
 Surface Roughness
2) Too rapid heating, it may cracks the investment resulting
in fins
it can be avoided by :-
- Heat the ring gradually to
7000C (in at least 1 hour)

3) Higher W/P ratio gives rougher casting. Larger particle

size of investment has the same effect
it can be avoided by :-
- Using correct W/P ratio &
select investment of correct
particle size
 Surface Roughness
4) Prolonged heating causes disintegration of the mould
cavity
it can be avoided by :-
- complete the casting as soon as the ring is heated &
ready
- Overheating of gold alloy has the same effect. It
disintegrates the investment.

5) Too high or too low casting pressure

it can be avoided by :-
- Using 15 lbs /sq inch of air pressure or three to
four turns of centrifugal casting machine
Rounded , incomplete margins are evidence
of insufficient casting pressure
 Surface Roughness
6) Composition of the investment. Proportion of the
quartz & binder influences the surface texture of casting.
Coarse silica will give coarse casting

7) Foreign body inclusion shows sharp, well

defined deficiencies.
 Porosity
◼ Porosity may be internal or external
◼ External porosity can cause discoloration of the casting
◼ Internal porosity weakens the restoration
◼ Severe porosity at the tooth restoration junction can
cause secondary caries
 Porosity
◼ Porosities are Classified as (Phillips)
1) Those caused by solidification shrinkage
➢ Localized shrinkage porosity
➢ Suck back porosity
➢ Microporosity
2) Those caused by gas
➢ Pin hole porosity
➢ Gas inclusions
➢ Subsurface porosity
3) Those caused by air trapped in the mould Back
pressure porosity
 Localized Shrinkage Porosity Or
Shrink Spot

◼ These are large irregular voids usually found

near the sprue-casting junction.
◼ It occurs when cooling sequence is incorrect &
the sprue freezes before the rest of the casting.
◼ During a correct cooling sequence, the sprue
should freeze last.
◼ This helps the molten metal to flow into the
mould to compensate for the shrinkage of the
casting as it solidifies.
Shrink Spot Or Localized Shrinkage
Porosity
◼ If the sprue solidifies before the rest of the
casting no more molten metal can be supplied
from the sprue.
◼ The subsequent shrinkage produces voids or pits
known as shrink-spot porosity
it can be avoided by :-
➢ using sprue of correct thickness
➢ Attach sprue to thickest portion of wax pattern
➢ Flaring the at the point of attachment or placing
a reservoir close to the wax pattern
SEQUENCE OF SOLIDIFICATION OF ALLOY
 Suck Back Porosity
◼ It is a variation of the shrink
spot porosity

◼ This is an external void usually

seen in the inside of a crown
opposite the sprue

◼ A hot spot is created by the hot metal impinging on

the mould wall near the sprue
◼ The hot spot causes this region to freeze last
◼ The sprue has already solidified, no more molten
material is available & the resulting shrinkage causes a
peculiar type of shrinkage called suck back porosity
◼ It is avoided by reducing the temperature difference
between the mould & the molten alloy
 Microporosity

◼ These are fine irregular voids within the casting

◼ It is seen when the casting freezes too rapidly

◼ Rapid solidification occurs when the mould or casting

temperature is too low
 Pin Hole Porosity
◼ Many metals dissolve gases when molten
◼ Upon solidification the dissolved gases are expelled
causing tiny voids, e.g.. platinum & palladium absorb
hydrogen
◼ Copper & Silver dissolve oxygen
 Gas Inclusion Porosity
◼ These are also spherical voids but are larger than
pin hole type

◼ They may also be due to dissolved gases, but are

more likely due to gases carried in or trapped by
the molten metal

◼ A poorly adjusted blow torch can also occlude

gases
 Back Pressure Porosity
◼ This is caused by inadequate venting (air escape) of the
mould

◼ The sprue pattern length should be adjusted so that

there is not more than 1/4th thickness of the
investment between the bottom of the casting ring &
the wax pattern

◼ When the molten metal enters the mould, the air inside
is pushed out through the porous investment at the
bottom
 Back Pressure Porosity
◼ If the bulk of the investment is too great, the escape of
air becomes difficult causing increased pressure in the
mould

◼ The molten metal will then solidify before the mould is

completely filled resulting in a porous casting with rounded
short margins
 Back Pressure Porosity
◼ Avoid by
1) Using adequate casting
force
2) Use investment of
adequate porosity
3) Place pattern not more
than 6 to 8 mm away from
the end of the ring
4) Providing vents in large
castings
 Incomplete Casting
◼ An incomplete casting may result when

1) Insufficient alloy used

2) Alloy not able to enter thin parts of mould
3) When mould is not heated to casting temperature
4) Premature solidification of alloy
5) Sprues are blocked with foreign bodies
6) Back pressure due to gases in mould cavity
7) Low casting pressure
8) Alloy not sufficiently molten or fluid
 Incomplete casting

Wax pattern too thin Incomplete wax elimination

 To bright and shiny casting with
short and rounded margins
◼ When the wax is not completely eliminated, it
combines with oxygen or air in the mould cavity
forming carbon mono-oxide which is a reducing
agent. The gas prevents the oxidation of the
surface of the casting gold with the result that
the casting which comes out from the
investment is bright and shiny. The formation of
gas in the mould is so rapid that it also has a
back pressure effect.
Incomplete casting resulting from incomplete wax
elimination is characterized by rounded margins &
shiny appearance
 Small casting
◼ If compensation for shrinkage of alloy is not done by
adequate expansion of mould cavity, then a small
casting will result. Another reason is, the shrinkage of
the impression material.
 Contamination

1. Due to oxidation when molten alloy is over heated

2. Use of oxidizing zone of the flame
3. Failure to use flux
4. Due to formation of Sulphur compounds

it can be avoid by :-
◼ Not overheating alloy
◼ Use reducing zone of the flame
◼ Use of flux
 Black casting
◼ Can be due to two reasons

1. Overheating the investment above 7000c causes it to

decompose liberating Sulphur or Sulphur compounds.
They readily combine with the metals in gold alloy
forming a sulphide film. This gives a dark casting which
cannot be cleaned by pickling.
2 A black casting, can be also due to incomplete
elimination of the wax pattern, as a result of
heating the mould at too low temperature. A
carbonized wax remains which sticks to the
surface of the casting. It can be removed by
heating over a flame.
 CONCLUSION

◼ An unsuccessful casting results in considerable trouble

& loss of time
◼ In almost all instances, defects in castings can be
avoided by strict observance of procedures governed by
certain fundamental rules & principles.
◼ Seldom is a defect in a casting attributable to factors
other than carelessness or ignorance of the operator
◼ With present technique the casting failure should be
the exception, not the rule.
 References

◼ Phillips science of dental material

◼ Contemporary fixed Prosthodontics, Rosenstiel
◼ Dental laboratory procedure for fixed partial
denture, Rudd & marrow
◼ Basics dental material, Manappallil