634014679023006250

Fundamentals
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

Casting
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
Casting
Sprue Former
Casting

Casting

Casting
Sprue Materials

Casting
Sprue Former Position

Often a matter of individual judgment,
based on the shape & form of the wax
pattern.
Some prefer placement at;
Occlusal surface
Proximal wall
Just below a nonfunctional cusp
Ideal area- point of greatest bulk in pattern .
Casting

Casting
Significance
1. To avoid distorting thin areas of wax
during attachment to the pattern.
2. To permit smooth flow of the alloy.
*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips

Casting
Sprue former Direction

The Sprue former should be directed away
from any thin or delicate parts of pattern.
It should not be attached at a right angle
to a broad flat surface. Sprueing should be
done at a 45-degree angle to the proximal
wall.

Casting

Casting
Maximum impedance to flow occurs when a

Sprue former makes an angle of 90-degree to the
pattern
*Laboratory Procedures for Full and Partial Dentures by
Derek Stanananought
Casting
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.
Casting
Sprue Former Length

The length of the Sprue former depends
on the length of the casting ring.
Length of the Sprue former should be such
that it keeps the wax pattern about 6 to 8
mm away from the casting ring.
Sprue former should be no longer than 2
cm.
The pattern should be placed as close to
the centre of the ring as possible.
*Laboratory Procedures for Full and Partial Dentures by Derek Stanananought
Casting

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.
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
Casting
The Crucible, Sprue and the Mould should be considered

as being a wedge shape: 1. correct
2. incorrect
*Laboratory Procedures for Full and Partial Dentures by Derek
Stanananought
Casting
Significance
Failure to cater for this may result in a
reduction in density of the casting by
the presence of voids called Porosity
*Laboratory Procedures for Full and Partial Dentures by Derek

Stanananought
Casting
Reservoir And Its Location

Reservoir portion of a Spruing system is a round
ball or a bar located 1mm away from the wax
pattern.
Reservoir should be positioned in the heat
centre of the ring.(Alleluia,1980; Ingersoll & Wandling,1986;
McLean,1980; Naylor,1986)
This permits the reservoir to remain molten for

longer and enables it to furnish alloy to the
pattern until they complete solidification process
*Introduction to Metal Ceramic Technology by W. Patrick Naylor

Casting
Reservoirs
Round ball reservoir & a bar reservoir also
called connector
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.
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 .
Casting
Direct Spruing Technique

Casting
Suck-back porosity
It can be seen at the junction of restoration and Sprue

Casting
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
Casting
Indirect Spruing Technique

The Connector bar is often referred to as a
reservoir bar
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

Casting
Phosphate-bonded Casting
Investments
Carbon-containing
Noncarbon-containing
Gray-black color because of the

presence of carbon even after
burnout.
Require a special liquid colloidal
silica instead of distilled water.
Generally recommended for
gold-based metal ceramic
alloys.
*Introduction to Metal Ceramic Technology

by W. Patrick Naylor
White color before and

after mixing.
Used with nickel- and
cobalt-base casting alloys,
as well as palladium-based
noble metal alloys.
Because these alloy
systems are capable of
dissolving available carbon
to produce carbides and/or
porosity (due to carbon
inclusions)

Casting
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.
Casting
Investment-Casting Alloy
Interaction
Variations can occur in the performance of
alloys with different investments (Barreto et al,1980;
Hinman et al,1985).
Nodule formation and fins may occur more

frequently with one brand of investment but not
with other.
Therefore, it is prudent to conduct laboratory
tests for adverse alloy-investment interaction
before making a large purchase of a new
product (Naylor,1990).
Casting
Rough casting with multiple nodules may be caused

by a less-than-ideal alloy-investment pairing
Casting
Casting Ring Liners

1. Asbestos Ring Liner:
Traditional material for lining casting rings until it
was learned that it posed a potential health risk to
dental laboratory technicians (Davis,1987; palmer et
al,1961; Priest & Horner, 1980).
Asbestos fiber bundles were found to produce

hazardous-size respirable particles capable of
causing lung disease.

Casting
Asbestos liner (original

magnification x 500)
Casting
2.
Non-asbestos Ring Liners:

Ceramic (aluminum silicate)
Cellulose (paper)
Ceramic-cellulose combination
Safety of the ceramic ring liners remains
uncertain, because aluminum silicate also
appears capable of producing hazardoussize respirable particles (Naylor et al,1987).

Casting
Casting Ring Lined by a Liner

Casting
Purpose of Casting Ring

Liner
Ringer liner is he most commonly used technique to
provide investment expansion.
To ensure uniform expansion , liner is cut to fit the
inside diameter of the casting ring with no overlap.
Thickness of the liner should not be less than
approximately 1mm.
Place the liner somewhat short of the ends of the ring,
3mm, tends to produce a more uniform expansion,
therefore less chance for distortion of the wax pattern
& mold.
Casting
Ring liner short of the ends of the

ring about 3mm

Casting
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.
Casting
Wax pattern cleaner being applied

with a camel hair brush

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

Casting
Vacuum power mixer

Casting
3. Investment material pouring

Casting ring is filled up to its rim.
Allow the investment to set for about 1
hour.
Crucible former is carefully removed.
If burnout procedure does not immediately
follow investing, place ring in humidor.
Casting
Investment material being poured

after vacuum mixing

Casting
4. Wax elimination & heating

Invested ring is placed in a room
temperature furnace.
Phosphate-bonded investments---temperature range----700 to 870*C
Temperature rate of rise for the
burnout furnace is 10*C/min
Casting
It is advisable to begin the burnout

procedure while the mould is still wet.
Water trapped in the pores of the
investment reduces the absorption of
wax.
As the water vaporizes it flushes wax
from the mold.
Casting
Melting & Casting Technique

Melting & Casting requires
1.Heat source to melt the alloy
2.Casting force, to drive the alloy into
the mould

Casting

Casting
Casting Torch Selection

Two type of torch tips:
1.Multi-orifice
2.Single-orifice
Multi-orifice tip is widely used for metal
ceramic alloys.
Main advantage is distribution of heat over wide
area for uniform heating of the alloy.
Single-orifice tip concentrate more heat in one
area.
Casting
*Introduction to Metal Ceramic Technology by W. Patrick

Naylor
Casting
Choice of Fuels
Three fuel sources are used for Casting
Torch
1.Acetylene
2.Natural Gas
3.Propane
*Dental Laboratory manual, 1982

Casting
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.
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.
Casting
When the reducing zone is in

contact, the surface of the gold alloy
is bright and mirror-like.
When the Oxidizing zone is in
contact the metal there is a dull film
of dross developed over the
surface.
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.

Casting
Air Pressure Casting Machine

Casting
Cradle
Counter
weight
crucible
Base
Centrifugal Casting Machine

Casting
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)
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.
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.
Casting
Hydrochloric acid
Sulfuric acid
Ultrasonic devices
Gold and palladium based metal
ceramic alloys and base metals, these
alloys are not generally pickled.

Casting
The Laws of Casting

Casting is both an art and science governed
by numerous rules, or laws.
Building on earlier work of Ingersoll &
Wandling (1986), W. Patrick Naylor
formulated an expanded set of 17 separate
recommendations for Spruing, investing,
burnout, and melting and casting procedures.
Collectively these guidelines are referred to
as the laws of casting.

Casting
The 1st Law of Casting

Attach the pattern Sprue
former to the thickest part of
the wax pattern
Casting
As the molten metal alloy moves from the

reservoir to the pattern margins it should flow
from areas of greater volume to areas of
lesser volume (ie, margins).
Lute the pattern Sprue former to the most
practical portion of the occlusal/incisal
surface.
Molten metal flowing from thin area to a
thicker region(full waxup) may solidify before
the mold is completely filled.
Casting
Penalties
Penalties for not obeying this law are:
Clod shuts
Short margins
Incomplete castings

Casting
The 2nd Law of Casting

Orient wax pattern so all the
restoration margins will face
the trailing edge when the
ring is positioned in the
casting machine
Casting
To identify that orientation, add a wax

dot to the crucible former so you
know how to place the ring in the
casting cradle correctly after the
pattern have been invested.

Casting

Naylor
Casting
Penalties
Penalties for not obeying this law are:
Cold shuts
Short margins

Casting
The 3rd Law of Casting

Position the wax pattern in a
cold zone of the investment
mold and the reservoir in the
heat centre of the casting
ring
Casting
The coolest parts of the mold (cold zones) are

the end of the ring and along the ring
periphery.
The hottest portion of the casting ring is located
near the centre of the ring (heat centre).
Limit the amount of investment covering the
patterns to no more than inch (6mm) &
position the reservoir in the heat centre.
Adherence to this law increases the likelihood
that casting porosity will occur in the reservoir
rather than in the restoration.
Casting

Naylor
Casting
Penalties
The penalty for not obeying this law is:
Shrink-age porosity

Casting
The 4th Law of Casting

A reservoir must have
sufficient molten alloy to
accommodate the shrinkage
that occurs within the
restorations
Casting
Alloy that fills the restoration will solidify

first.
As the molten metal solidifies, it shrinks
and creates a vacuum.
For a complete casting, the vacuum
must be able to draw additional metal
from an adjacent source--the reservoir.
Reservoir should be equal to or greater
than the thickest cross-section area of
the wax pattern.
Casting
Penalties
The penalty for not obeying this law are:
Shrink-age porosity
Suck-back porosity

Casting

Do not cast a button if a
connector (runner) bar, or
other internal reservoir, is
used
Casting
With indirect Spruing, the largest mass

of metal should be the reservoir.
A button is counterproductive because it
can draw available molten alloy from
the bar, shift the heat centre and reduce
the feed of that metal to the
restorations.
Likewise, the wax pattern should not
be larger than the connector bar
shift the heat centre.
Casting

Naylor
Casting
Penalties
The penalties for not obeying this law
are:
Shrinkage porosity (and potential
Distortion during porcelain firing)
Suck-back porosity

Casting

Turbulence must be
minimized, if not totally
eliminated
Casting
Pathways for the flow of metal should be

smooth, gradual, and without impediments.
Eliminate sharp turns, restrictions, points, or
impingements that might create turbulence
and occlude air in the casting.
Restrictions, or constrictions, can accelerate
the metal's rate of flow and abrade the
mold surface (Ingersoll & Wandling,1986).

Casting
Penalties
The penalties for not obeying this law are:
Voids in the casting ring
Surface pitting

Casting

Select a casting ring of
sufficient length and diameter
to accommodate the patterns
to be invested
Casting
The casting ring should permit the patterns to be

in. apart and in. from the top of the
investment with a minimum 3/8 in. of investment
between them and the ring liner.
If too little investment covers the wax
patterns, the alloy is more likely to break through
he mold.
Too much investment over the waxups may
locate the wax patterns too close to the heat
centre of the mold and impair the escape of gases.

Casting

Casting
Penalties
are:
Mold fracture
Casting fins
Shrinkage porosity

Casting

Increase the wettability of the
wax patterns

Casting
A wetting agent should be brushed or

sprayed on the patterns and dried before
investing.
A clean wax surface better enables the
casting investment to wet the patterns
more completely.
Too much wetting agent can create a
surface film that can dilute and weaken
the investment in that area and produce
bubbles or fins on the casting.
Casting
Apply a thin layer of debubblizer (wax

pattern cleaner) to the wax patterns and
indirect Spruing system and allow it to
dry thoroughly before investing
Casting
Penalties
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).

Casting

Weigh any bulk investment
and measure the investment
liquid for a precise powderliquid ratio
Casting
The correct proportion of powder to liquid and

any dilution of the (special) liquid with distilled
water should be established for each alloy.
A thick mix of investment (reduced liquid)
increases investment expansion & produces
loose-fitting castings.
Too much liquid results in thinner mix and
less expansion with tighter-fitting castings.
Using all special liquid provides more
expansion but reduces working time compared
to 50:50 dilution of the special liquid and
distilled water.
Casting
Penalties
Ill-fitting castings

Casting
The 10th Casting Law

Eliminate the incorporation of
air in the casting investment
and remove the ammonia gas
by product of phosphatebonded investments by
mixing under vacuum
Casting
Vacuum mixing removes more air and

gas than hand spatulation.
Ares of the mold that contain dense,
bubble-free investment will expand
differently from sections that contain
large voids (entrapped air).

Casting
Penalties
Small Nodules on the casting
Weak mold
Distortion of the casting

Casting

Allow the casting investment
to set completely before
initiating the burnout
procedure
Casting
If setting is not complete at the time a ring

is placed in the oven, the mold may be weak
and unable to withstand steam expansion
during burnout.
Investment could fracture as a consequence.
For best results, burnout should be initiated
only after the recommended setting time.

Casting
Penalties
Mold crackling/Blowout
Fins on the casting

Casting

Use a wax elimination
(burnout) technique that is
specific for the type patterns
involved (wax versus plastic)
and recommended for the
particular type of casting alloy
Casting
Plastic Sprues need to be heated slowly so

they can soften gradually and not exert
pressure on the mold, so use a two-stage
burnout (Tombasco & Reilly,1987).
If burnout is incomplete, the spruing system
channels may be blocked by wax or plastic
residue (carbon) and, on casting, air cannot
escape completely when metal enters the mold
(Naylor,1990a; Tombasco & Reilly,1987).
Therefore, use at least a 30-minute heatsoaking at 800 *F for the first burnout stage.
Casting
Penalties
The penalties for not obeying this laws
are:
Cold Shuts
Short Margins
Cold Welds
Mold Cracks
Casting Fins
Casting

Adequate heat must be
available to properly melt and
cast the alloy (Myers,1936)
Casting
The selected heat source should be

capable of melting the alloy to the point
of sufficient fluidity.
Prolonged heating, caused by an
improperly adjusted torch, can prevent
the alloy from attaining the fluidity.
Too much heat, or too high
temperature, can burn off minor alloying
elements.
Casting
Penalties
are:
Cold Shuts
Short Margins
Cold Welds (too little heat)
Rough Castings
Investment Breakdown (too much heat)
Casting

When torch casting, use the
reducing zone of the flame
to melt the alloy and not the
oxidizing zone
Casting
An improper adjusted torch can add

carbon or oxygen to the alloy while
heating.
A melt achieved by the exclusive use of
the Reducing zone minimizes the
likelihood of metal oxidation and gas
absorption and ensures a proper melt.
Casting

Naylor
Casting
Penalties
Gas porosity
Change in the alloys Coefficient of
thermal expansion (due to alloy
contamination)

Casting

Provide enough force to cause
the liquid alloy to flow onto
the heated mold
Casting
Adjust the casting machine to the

requirements of each alloy.
Lower-density metals generally need
four winds of a centrifugal casting arm as
compared to higher-density, gold based
alloys.
Don't over wind.
Casting
Penalties
are:
Cold Shuts
Short Margins
Clod Welds (insufficient force)
Mold Fracture & Fins (too much force)

Casting

Cast toward the margins of
the wax patterns

Casting
Place the heated ring in the casting cradle

using the orientation dot so the pattern
margins face the trailing edge (the 2 nd
law).
In a centrifugal casting machine the metal
will flow downward and to the right, taking
advantage of the centrifugal, rotational,
and gravitational forces of molten alloy
(Ogura et al,1981; Ingresoll & Wandling,1986).

Casting
Penalties
are:
Cold shuts
Short margins
Incomplete castings

Casting

Do not quench the ring
immediately after casting

Casting
Allow the alloy and the investment to

cool to room temperature.
Uneven cooling and shrinkage between
alloy and investment can apply tensile
forces to the casting (Cascone,1976).
After casting, the alloy may not possess
sufficient strength to resist these forces
and the restoration could tear, if
quenched.
Casting
Penalties
Hot Tears in the restoration

Casting
Analyzing Casting Failures

Despite concreted efforts to follow the recommended
procedures, casting failure & mishaps are bound to
occur in the laboratory.
By standardizing our technique & paying strict attention
to each step, it is often possible to control the location
of the solidification shrinkage & minimize the number of
actual miscasts.
When casting failures do occur, we should troubleshoot
each miscast to diagnose the cause of the problem so
corrective measures may be taken before we make
additional casting.
Casting

Naylor

Casting
Thank You!

Casting

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Fundamentals

Fundamentals of Spruing, Investing &

*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips

Fundamentals of Spruing, Investing &

*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips

Sprue Former Position

Fundamentals of Spruing, Investing &

*Skinners Science of Dental materials 9th Edition by Ralph W. Phillips

Sprue former Direction

*Skinners Science of Dental materials 9 th Edition by Ralph W. Phillips

Fundamentals of Spruing, Investing &

Maximum impedance to flow occurs when a

Sprue Former Length

Fundamentals of Spruing, Investing &

The Crucible, Sprue and the Mould should be considered

*Laboratory Procedures for Full and Partial Dentures by Derek

Reservoir And Its Location

This permits the reservoir to remain molten for

Fundamentals of Spruing, Investing &

Direct Spruing Technique

Fundamentals of Spruing, Investing &

Fundamentals of Spruing, Investing &

Indirect Spruing Technique

*Introduction to Metal Ceramic Technology by W. Patrick Naylor

Fundamentals of Spruing, Investing &

Gray-black color because of the

*Introduction to Metal Ceramic Technology

White color before and

Fundamentals of Spruing, Investing &

Nodule formation and fins may occur more

Rough casting with multiple nodules may be caused

Casting Ring Liners

Asbestos fiber bundles were found to produce

*Introduction to Metal Ceramic Technology by W. Patrick Naylor

Fundamentals of Spruing, Investing &

Asbestos liner (original

Non-asbestos Ring Liners:

*Introduction to Metal Ceramic Technology by W. Patrick Naylor

Casting Ring Lined by a Liner

Fundamentals of Spruing, Investing &

Purpose of Casting Ring

Ring liner short of the ends of the

Fundamentals of Spruing, Investing &

Wax pattern cleaner being applied

Fundamentals of Spruing, Investing &

Fundamentals of Spruing, Investing &

Vacuum power mixer

Fundamentals of Spruing, Investing &

3. Investment material pouring

Investment material being poured

Fundamentals of Spruing, Investing &

4. Wax elimination & heating

It is advisable to begin the burnout

Melting & Casting Technique

Fundamentals of Spruing, Investing &

Fundamentals of Spruing, Investing &

Casting Torch Selection

*Introduction to Metal Ceramic Technology by W. Patrick

*Dental Laboratory manual, 1982

When the reducing zone is in

Fundamentals of Spruing, Investing &

Air Pressure Casting Machine

Centrifugal Casting Machine