Sprue

A sprue is the channel in a refractory investment mold through which

molten metal flows.
Sprue can be defined as the channel created in the investment through
which the molten metal enters the mold space created by the burnout
of the wax pattern. Sprue formers are materials that form these
sprues. Sprue formers may be made of wax, metal, or plastic/resin.
Basic Requirements of the Sprue:
• The sprue former should not leave any residue during burnout.
• The size, number, direction, and location of the sprue should be such
that it allows uninterrupted passage of molten metal into the entire
mold.
• The molten metal in the sprue should remain molten slightly longer
than that within the mold, acting as a reservoir to compensate for the
casting shrinkage of the metal during solidification.
Materials used :
Wax is the preferred material of choice for sprue formers since it melts at the
same rate as the wax pattern and thus allows easy escape of the molten wax.
Plastic/acrylic sprues are used in multiunit bridges and cast partial dentures due
to their rigidity, which minimizes distortion. But plastics melt at a much higher
temperature than wax and may block the escape of the molten wax causing
casting roughness. Hollow plastic sprues are available, which help in eliminating
the molten wax easily.
For inlays, metal sprue can be used since it increases surface contact area and
strengthens the attachment between the pattern and the sprue. This enables
careful removal of the wax pattern from the master die. Hollow metal sprues
are preferred since solid metal sprue retains and transmits heat from the
softened wax and leads to distortion of the wax pattern. It also takes a longer
time for the wax to harden due to the thermal conductivity of the metal leading
to further distortion.
Dimensions of a Sprue Former :
1. Diameter: The diameter depends on the thickness of the wax pattern. The
diameter should be approximately equal to the thickest portion of the wax
pattern.
If the sprue diameter is too small, the molten metal in the sprue will
solidify before the casting itself, thus resulting in localized shrinkage
porosity (suck-back porosity). Smaller sprue diameters for larger wax
patterns can be compensated by adding reservoirs, this will enable the
continuous flow of molten metal and prevent premature solidification of
the sprue.
If the sprue diameter is too large, it may distort the thin and delicate wax
pattern resulting in defective casting.
2. Position: Generally, sprues should be attached to the widest part of the
wax pattern to allow proper flow of the molten metal. Placement on the
margins should be avoided to prevent distortion and tearing of the
margins. Normally the largest non-centric cusp is used.
3. Direction: The sprue former is attached at an angle of 45° to the thickest
part of the wax pattern. Attaching at 90° directly to the wider surface area
results in turbulence in the flow of molten metal and severe porosities in
the casting. Direction of the sprue should also be away from any thin
portion of the wax pattern because molten metal may abrade or fracture
investment material in this area resulting in casting failure.
4. Attachment: The dimension of the connection between sprue former and
the wax pattern depends on the density of the metal to be cast. The sprue
should be flared as it is attached to the wax pattern to allow entry of the
molten metal freely into the mold. Since the sprue is attached to the
widest part of the pattern, molten metal will flow from the thicker section
of the mold to the surrounding thinner areas such as the margins. This
minimizes the risk of turbulence and prevents formation of hot spot.
5. Length: The length of the sprue depends on the length of the casting ring.
The sprue former length is adjusted so that the upper end of the wax
pattern is within 6 mm (¼th inch) of the open end of the casting ring for
gypsum-bonded investments and within 3–4 mm (⅛th inch) for higher
strength phosphate-bonded investments. This provides adequate strength.