Casting procedures

Dr. Kriti trehan

MDS 1st
year
13/3/18
 CONTENTS

Introduction
Steps in casting procedure
Wax pattern removal
Sprue formers
 Crucible formers
 Casting rings and ring liners
 Investing procedure
Wax burnout
 Casting of alloys into mold
 Casting of titanium alloys
Cleaning of casting
 Introduction
 Casting is one the most widely used methods for
fabrication of metallic restorations.

 The lost wax casting technique was first described at the

end of 19th century as a means of making dental castings.

 The process consists of surrounding the wax pattern with

a mold made of heat resistant investment material,
eliminating the wax by heating and then introducing the
molten metal into the mold through a channel called
“Sprue”.
• In Dentistry, the resulting casting must be a highly accurate
replica of wax pattern with surface details & accurate
dimensions.

• Small variations in investing or casting can significantly

affect the quality of final restoration.

• Successful casting depends on accuracy &

consistency of
technique.

• We are going to know the exact influence of each variable in

the technique & to make rationale changes to modify the
technique according to need.
Steps in casting procedures

1. Wax pattern removal

2. Spruing
3. Investing
4. Burnout
5. Casting
 Wax patterns
 First procedure in the casting of an inlay or crown for
the lost-wax process is the preparation of a dental wax
pattern.

 Direct Wax Technique – Pattern made within the tooth.

Indirect Wax Technique – Pattern prepared within a die.

 INLAY WAX – Specialized dental wax applied on the die

surface for preparation of direct & indirect patterns

 American National Standards Institute / American Dental

Association Sp No 4:
o Type I – Medium Wax – Direct techniques
o Type II – Soft Wax – Indirect techniques
INDIRECT TECHNIQUE DIRECT TECHNIQUE
REMOVAL OF WAX PATTERN

Direct pattern:

 Sprue former  Attached to the pattern  Removed directly

in line with its path of withdrawl .

 Hook it with an explorer point and rotate it out of the cavity .

 In a MOD use a staple pin . Fasten it and insert a floss

and hook it .
Indirect patterns:
 The wax should be allowed to cool
thoroughly before the pattern is
removed from the die.

 A constant light grip is maintained

on the pattern by the thumb and
forefinger of one hand while
pressure is applied against them
with the thumb and forefinger of the
other hand, which also holds the
die
 Sprue
When the wax pattern has been completed and its margin
has been reflowed, it is carefully evaluated for smoothness,
finish, and contour.

 The pattern is inspected under magnification, and any

residual flash is removed. A sprue is attached to the
pattern, then removed from the die and fitted to a crucible
former.

Sprue : The channel or hole through which plastic or

metal poured or cast into gate or reservoir and then
into mold.
1. Basic requirements of sprue:

a) Must allow the molten wax to escape from the mold.

b) Sprue must enable the molten metal to flow into the mould
with as little turbulence as possible.

c) Metal must remain molten slightly longer than the alloy that has
filled the mould. This provides a reservoir to compensate for
the shrinkage that occurs during solidification of the casting.
2. Types of sprue :
 The sprue can be wax, plastic, or metal.

a) Wax sprues are preferred for most castings because they

melt at the same rate as the pattern and thus allow easy
escape of the molten wax.
b) Solid plastic sprues soften at a higher temperature than the
wax pattern and may block the escape of wax, resulting in
increased casting roughness.

 However, plastic sprues can be useful when casting fixed

partial dentures (FPDs) in one piece because their added
rigidity minimizes distortion. Also, hollow plastic sprues are
available that permit the escape of wax.
c) If a metal sprue is used, it should be made of nonrusting
metal to avoid possible contamination of the wax.

 Metal sprues are often hollow to increase contact

surface area and strengthen the attachment between the
sprue and pattern.

 They are usually removed from the investment at the

same time as the crucible former.

 Special care must be taken to examine the orifice for

small particles of investment that may break off when such
a sprue is removed because these can cause an
incomplete casting if undetected.
 Sprue former diameter

 The diameter and length of the sprue former depends on:

 The type and size of the pattern.
 The type of casting machine to be used.
 The dimensions of the casting rings in which
casting is made.

 Pre fabricated sprue former are available in a wide variety of

gauge from 6 to 18.

 The diameter of sprue should be equal to the thickest

portion the wax pattern.
 Usually for molar and metal ceramic restoration - 10-gauge
(2.5mm)

 Premolars and partial coverage restoration - 12-gauge

(2.0mm)

 Large diameter sprue: this improves the flow of molten metal

into the mould.

 Small diameter sprue: this area will solidify before the

casting itself and localized shrinkage porosity (“suck-back”
porosity) may develop.
4. Length of the sprue former

 Should be long enough to properly position the pattern

in the casting ring within 6 mm of the end of the ring yet
short enough so that the molten alloy doesn’t solidify before
it fills the mold . ( 6mm – Gypsum bonded investments & 3-
4mm – Phosphate bonded )
 Average sprue length – Large inlay – 4-5mm
Small inlay – 3-4mm

 Short sprue – Moves the pattern more away from the

end of the ring and the gases cannot be adequately vented.

 Long sprue – Solidify before the mold causing

shrinkage porosity.
5. Sprue former location:

 The sprue should be attached to the bulkiest part of the

pattern, away from margins and occlusal contacts.

 Normally the largest noncentric cusp is used.

 The point of attachment should permit a stream of metal to
be directed to all parts of the mold without having to flow
opposite the direction of the casting force.

 Full veneer crown - sprue is attached to Maxillary buccal

and
mandibular lingual cusp.

 Partial veneer crown - sprue is attached to cusp

that encompasses the preparation.
6. Sprue former direction:

 Should be directed away from any thin or delicate parts of

pattern - molten metal may abrade or fracture investment in
this area.

 It should be attached 45 degrees to the walls of mold, which

decreases the turbulence of molten alloy.
. Sprue former attachment :

 The attachment of sprue former to the wax pattern should be

smooth and do not posses pits or irregularities.

 Irregularities produces tags of investment which is prone

for fracture by molten alloy leading to casting failure.

 The sprue former connection to the wax pattern is generally

flared for high-density gold alloys but often restricted for
lower-density alloys.

 This design minimizes the risk of turbulence. Also, the

orientation of the sprue former should minimize the risk for
metal flow onto flat areas of the investment or onto small
areas such as line angles.
 Reservoir:

 The reservoir is placed approximately 1.5mm from the

pattern .

 Function – Prevents localized shrinkage porosity, because of

the large mass of alloy and position in the heat centre of the
ring , the reservoir will remain molten to furnish liquid alloy
into the mold as it solidifies .

Reservoir
Venting :
• Small auxiliary sprues or vents have been recommended to
improve casting of thin patterns and may help in :
 Escape of gases during casting.

 Compensate for the shrinkage during solidification.

 Solidification begins in critical areas by acting as a heat

sink.
 Spruing technique

DIRECT INDIRECT

• The sprue former

provides a direct • A connector or reservoir
connection between the bar is positioned
pattern area and the between the pattern and
sprue base or crucible the crucible former
former area.
 Crucible former
 The sprue is attached to crucible former which constitutes
the base of the casting ring during investing.

 It also helps by holding sprue in desired ring.

 Crucible formers are basically of 2 types:

a) Steep-sided cone: used with metal when casted using
centrifugal casting force.

b) Shallow cone: used to cast metal using stream/air

pressure.
 They are available as-
 Rubber crucible former
 Metallic Crucible former
 Plastic crucible former
 The exact shape of the crucible former depends on the type
of casting machine used.

 With most modern machines, the crucible former is tall to

allow use of a short sprue and allow the pattern to be
positioned near the end of the casting ring.

 They form a conical depression in investment, which guides

flow of molten metal.

 It should be clean and petroleum is applied to

prevent formation of rough investment tag.

 Then the end of sprue former is passed into the hole and
held in position till the molten wax sets.
 Casting ring
 Casting rings are used to confine the fluid investment around the
wax pattern while the investment sets.

 It also allow the hardened investment to be safely handled

during burnout and casting.

 The internal diameter of casting ring should be 5-10mm

greater than the widest measurement of the pattern and about
6 mm higher.

 For single crown/inlay - small rings are used, diameter - 32

mm

 For large fixed partial denture – 63mm round/oval shaped

casting ring are used.
 Types of casting ring

SPLIT
SHAPE
COMPLETE
•Round RING RING
•Rigid : Metal , • Metal
•Oval
plastic • Plastic
•Flexible:
Rubber
RING LESS CASTING SYSTEM

 Ringless Casting System is designed to increase

productivity by achieving consistently accurate results
without the time-consuming steps associated with the use of
metal casting rings.

 Utilizes durable, reusable plastic rings that are tapered

allowing for unimpeded expansion of investment and easy
removal of mold prior to burnout.

 This allows for quick and easy divesting after casting while
reducing clean-up chores.

 Investment expansion is easier to control and not limited to

the thickness of a ring liner.
 Casting ring liners
 The most commonly used technique to provide room for
investment expansion.

 Triple fold function : - Freedom to expand which

would otherwise be restricted by the ring .

 Helps to offset the contraction of the more rapidly cooling

ring while the gold alloy is being melted .

 In a wet liner certain amount of hygroscopic

expansion is afforded and a thicker liner provides even
greater semi hygroscopic expansion.
• Asbestos liner: Asbestos is refractory to high temperature,
they show a sufficient amount of water absorption.

• There are 3 types of asbestos

i. White asbestos (least toxic) this type is used in
dentistry.
ii. Blue asbestos (most toxic)
iii. Brown asbestos(Intermediately toxic).

 Asbestos is no longer used in dentistry because of its

carcinogenic and toxic potential.
• Cellulose liner: This material shows adequate water
absorption.

• It is burnt during burnout procedure.

• To keep the investment in contact with ring after burnout,the

liner is kept 3mm short of ring ends.

• This also restricts the longitudinal setting and

hygroscopic expansion.
• Ceramic ring liner They are basically alumino-silicate
fibrous material.

• They do not absorb water to large extent, but its

network of
fibres can retain small amount of water on its surface.

• They are refractory to high temperature.

• The binders used in ceramic liner (Ex – neoprene-latex)

can contribute to toxicity (stimulate fibrosis/ act as
adsorbent surface for carcinogenesis).

• They posses fibers of length 5.3-17.8 mm. Diameter 0.2-

0.97 mm
 Disadvantages: Burned away during casting , difficult
to
secure in place.

 Absorb materials much less than asbestos , and

their combination with some gypsum bonded
investments will produce fins .

 Not compatible with phosphate bonded investments.

 Manipulation of a casting ring liner
 Cut the liner to fit the inside diameter of the casting ring , no
over lap.

 Dry liner technique – Dry liner is tacked in position with

sticky wax .
 Wet liner technique –Lined ring is immersed in water and
excess water is shaken away .

 Avoid touching or adapting with fingers - reduce

the cushioning effect.

 Attach the liner firmly to the ring by wax to prevent it

from “riding up” during investing and inadvertently
affecting the size of the casting
 Investing

The process of covering or enveloping an object such

as a denture, tooth, wax form, crown, with a suitable
investment material before processing, or casting

Investment materials are:

 Gypsum bonded investment
 Phosphate bonded investment
 Ethyl silicate bonded investment
Investing procedure :
• The wax pattern should be cleaned of any debris, grease, or
oils.

• A commercial wax pattern cleaner or a diluted synthetic

detergent may be used.

• Any excess liquid is shaken off, and the pattern is left to air-
dry while the investment is being prepared.

• The thin film of cleanser left on the pattern reduces the

surface tension of the wax and permits better “wetting” of the
investment to ensure complete coverage of the intricate
portions of the pattern
• Vacuum mixing of investment materials is highly
recommended for consistent results in investing and casting
with minimal surface defects, especially when phosphate-
bonded investments are used.

Vacuum investing machines.

The Whip Mix combination unit Girrbach Vacumat
• Air bubbles that remain in the mix, even with vacuum mixing,
can be entrapped on flat or concave surfaces that are not
oriented suitably for air evacuation.

• Tilting the ring slightly aids in releasing these bubbles so that

they can rise to the surface.

• Excessive vibration should be avoided because it can cause

solids in the investment to settle and may lead to free-water
accumulation adjacent to the wax pattern, resulting in
surface roughness.

• Excessive vibration can also dislodge small patterns from

the sprue former , resulting in a miscast.
• If the hygroscopic technique is employed, the filled casting
ring is immediately placed in a 37 °C water bath with the
crucible former’s side down.

• For the thermal expansion or high-heat technique, the

invested ring is allowed to bench set undisturbed for the time
recommended by the manufacturer.
 Wax elimination
 Wax elimination or burnout consists of heating the investment
in a thermostatically controlled furnace until all traces of
the wax are vaporized.

 Once the investment has set for an appropriate period 1 hour

it is ready for burnout.

 The crucible former is then carefully removed and the

invested rings are placed in a room temperature furnace
and heated to the prescribed maximum temperature.
 ut
ovens

Semiauto- Fully
Manual matic Programm-
able controls
• For gypsum-bonded investments, this temperature
can be either 500 °C for the hygroscopic technique or 700
°C the thermal expansion technique.

• With phosphate-bonded investments, the maximum

temperature setting may range from 700 °C to 1030 °C,
depending on the type of alloy selected.

• It is also advisable to begin the burnout procedure while the

mold is still wet. Water trapped in the pores of the
investment reduces the absorption of wax, and as the water
vaporizes, it flushes wax from the mold.
 When the high-heat technique is used, the mold temperature
generates enough heat to convert carbon to either carbon
monoxide or carbon dioxide. These gases can then escape
through the pores in the heated investment.

 Hygroscopic low-heat technique

 This technique obtains its compensation expansion from
three sources:
1) 37 °C water bath expands the wax pattern,
2) The warm water entering the investment mold from the top
adds some hygroscopic expansion
3) The thermal expansion at 500 °C provides the
needed thermal expansion.
 The molds should remain in the furnace for at least 60 minutes,
and they may be held up to 5 hours longer with little damage.

 Even though the mold is usually held at this temperature for 60

to 90 minutes, sufficient residual fine carbon may be retained
to reduce the venting of the mold.

 Because of this potential for reduced venting, back-

pressure porosity is a greater hazard in the low-heat
technique.

 Advantages:
i. Less investment degradation
ii. A cooler surface for smoother castings
iii. The convenience of placing the molds directly in the
500°C furnace.
iv. The last benefit makes it possible to keep one or more
furnaces at the burnout temperature so that molds may be
put in as they are ready.
 The standardized hygroscopic technique was developed for
alloys with a high gold content; the newer noble alloys may
require slightly more expansion.

 This added expansion may be obtained by making one or

more of the following changes:
 Increasing the water bath temperature to 40 °C
 Using two layers of liner
 Increasing the burnout temperature to a range of 600 °C to
650 °C

• In the low-heat casting technique, the alloy should also be

cast soon after removal of the ring from the oven; otherwise
a significant variation from the desired casting dimensions
may occur.
High-heat thermal expansion technique :
 Gypsum bonded Investment : •

o These casting investments are relatively fragile and require

the use of a metal ring for protection during heating.

o The molds are usually placed in a furnace at room

temperature, slowly heated to 650 °C to 700 °C in 60
minutes, and held for 15 to 30 minutes at the upper
temperature.

o Too rapid a heating rate may also cause cracking of the

investment. In such a case, the outside layer of the
investment expands much more than the center sections.
 Investment decomposition and alloy contamination
is related to a chemical reaction between the
residual carbon and calcium sulfate binder.

 The reduction of calcium sulfate by carbon takes

place rapidly above 700 °C in accordance with the
following reactions.

• CaSO4 + 4C= CaS + 4CO

• 3CaSO4 + CaS → 4CaO + 4SO2

 The sulfur dioxide as a product of this reaction

contaminates gold castings and makes them
extremely brittle.
 Therefore , after the casting temperature has been reached,
the casting should be made immediately.

 Maintaining a high temperature for a considerable

length of time may result in sulfur contamination of the
casting and also in a rough surface on the casting because
of the disintegration of the investment.

 A few gypsum investments, some with a considerable

amount of cristobalite, are now offered for use with a much
more rapid burnout procedure.
 Phosphate bonded investment :

o They need higher 2nd stage temperature for total

elimination of wax and to prevent premature
solidification of higher melting alloys.

o After the temperature reaches 400 °C, the rate of

heating can be safely increased. After burnout, usually at
a final temperature of 700 °C to 1030 °C depending on
the alloy melting range, the casting is made.

o Because the entire process involving phosphate investments

takes a long time, the demand for time-saving changes is
strong.
Accelerated casting method :
 Conventional casting techniques require considerable time,
typically 1 hour bench set for the investment and 1 to 2
hours for the wax elimination.

 Accelerated casting procedures have been proposed

that reduce this time to 30 to 40 minutes .

 Initially suggested as a way to make cast post-and-core

restorations in a one-visit procedure.

 The technique uses a phosphate-bonded investment that is

given approximately 15 minutes bench and a 15-minute wax
elimination by placing the ring in a furnace preheated to 815°
C (1500° F).
 CASTING

Something that has been cast in a mold; an

object formed by the solidification of a fluid that
has been poured or injected into a refractory
mold.(GPT-9)

Casting procedure: It is a process of obtaining a metallic

duplicate of a missing tooth structure by pouring molten metal
into a mold of a required form & allowing it to solidify to
obtain a metallic duplicate.
 CASTING MACHINES

Alloys are melted in one of the four following ways:

TORCH
ELECTRICAL
•Gas/Air (Most Common) Gas/Oxygen Resistance
•Air /Acetylene Oxygen /Acetylene Induction
Direct Current
Arc
Types of torch flame :

Gas air torch :
 Gas-air torch is used to melt conventional noble metal alloys
(used for inlays, crown and bridge) whose melting points
less than 1000⁰c.

Gas oxygen torch

 Used to melt metal ceramic alloys of higher temperature up
to 1200⁰c. The tip of torch is available as single
orifice/multiorifice the oxygen pressure is adjusted to 10-15
psi.

 The flame is directed onto metal with the nozzle of the torch
about 1.5 cm away from the metal.

 Complete fluid should be obtained within 30

second at which point the metal is poured into the
mould.
Air acetylene & oxygen acetylene gas
 These were designed mainly for Cobalt chromium
base alloys.
 The actual production of flame can be done by adjusting the
pressure and flow of individual gases .
 One part of acetylene + 2 and half part of oxygen

Advantage : Hottest flame hence faster burnout .

Disadvantages : Excessive heat may distill lower melting

components .
 Overheating – gases to dissolve in the casting –
porosity
 Highly technique sensitive
 The best results are obtained when flame is used with a
distance of 10cm between the face of blow torch nozzle and
the base of crucible.

 When the reducing zone is in contact, the surface of the gold

alloy is bright and mirror like.

 When the oxidizing portion of the flame is in contact with

alloy there is a dull film developed over the surface
 TORCH MELTING OF NOBLE METAL ALLOY

 The alloy is melted in a separate crucible by a torch flame

and cast into the mold by centrifugal force.

 Temperature of gas-air flame is influenced by :

 Nature of the gas
 Proportion of gas and air in the mixture.

• Two types of flames can be obtained with a casting torch, the

air supply for the lower flame is excessive, so that
incomplete combustion and a lower temperature will result.

• The upper brush flame indicates the proper adjustment for

maximal efficiency and temperature.
 The parts of the flame can be identified by the conical areas:
 The first long cone emanating directly from the nozzle is the
zone in which the air and gas are mixed before
combustion. No heat is present in this zone.

 The next cone, which is green and immediately surrounding

the inner cone, is known as the combustion
zone. Here, the gas and air are partially burned.
This zone is definitely oxidizing and
should always be kept away from the
molten alloy during fusion.
 The next zone, dimly blue and located just beyond the tip of
the green combustion zone, is the reducing zone.

 This is the hottest part of the flame, and it should be kept

constantly on the alloy during melting.

 The outer cone (oxidizing zone) is the area in which

combustion occurs with the oxygen in the air.

 Under no circumstances should this portion of the flame

be used to melt the alloy. Not only is its temperature lower
than that of the reducing zone but it also oxidizes the alloy
 The alloy first appears to be
spongy and then small globules of
fused alloy appear. The molten
alloy soon assumes a spheroidal
shape.

 At the proper casting

temperature, the molten alloy is
light orange and tends to spin or
follow the flame when the latter is
moved slightly.
 At this point, the alloy should be approximately 38 °C to 66

Flux:
 Flux for gold crown and bridge alloys to aid in minimizing
porosity.

 When properly used, the flux increases the fluidity of the

alloy and the film of flux formed on the surface of the molten
alloy helps prevent oxidation.

 Reducing fluxes are excellent for cleaning old alloy, a better

flux for the casting procedure may be made from equal parts
of fused borax powder ground with boric acid powder.
 The boric acid aids in retaining the borax on the surface of
the alloy. The flux is added when the alloy is completely
melted and should be used with both old and new alloy.

 Old sprues and buttons from the same alloy may be

recast if
they are not contaminated.
B. Electrical resistance–heated casting machine :

 During electrical melting of alloys heat energy is produced

when electric current is passed through a conductor
depending upon the voltage applied across it.

 The alloy is melted electrically by a resistance heating .

 Current is passed through a resistance heating conductor,

and automatic melting of the alloy occurs in a graphite or
ceramic crucible.

 A carbon crucible should not be used in the melting of high-

palladium alloys, palladium-silver alloys, nickel-chromium
alloys, or cobalt chromium base metal alloys.
 This is an advantage, especially for
alloys such as those used for metal-
ceramic prostheses, which are alloyed
with base metals in trace amounts
that tend to oxidize on overheating.

 Another advantage is that the crucible

in the furnace is located flush against
the casting ring. Therefore, the alloy
button remains molten slightly longer,
again ensuring that solidification
progresses completely from the tip of
the casting to the button surface.
C. Induction melting machine :

 With this unit, the alloy is melted by an induction field that

develops within a crucible surrounded by water-cooled metal
tubing .

 The electric induction furnace is a transformer in which an

alternating current flows through the primary winding coil
and generates a variable magnetic field in the location of the
alloy to be melted in a crucible.

 Once the alloy reaches the casting temperature in air or in

vacuum, it is forced into the mold by centrifugal force, air
pressure, or vacuum. It is more commonly used for melting
base metal alloys.
k
D. Direct-current arc melting
machine :

 The direct-current arc is produced between two electrodes:

the alloy and the water-cooled tungsten electrode. The
temperature within the arc exceeds 4000 °C and the alloy
melts very quickly.

 This method poses a high risk of overheating the alloy, and

damage may result after only a few seconds of prolonged
heating.
E. Vacuum- or pressure-assisted casting machine

 First evacuate the melting chamber to reduce

oxidation.

 Apply air pressure uniformly about the casting ring forcing

molten alloy into mold.

Vacuum is applied to the bottom of

the mold.

Molten alloy is “PUSHED & SUCK

ED” into the mold by gravity or vacuum.

 Used for titanium and titanium

CASTING CRUCIBLES:

 The melting of alloy requires a crucible to act as a platform

on which the heat can be applied to the metal.
 Generally four types of casting crucibles are available: clay,
carbon, quartz, and zirconia-alumina.

 Traditionally a wet lining of asbestos sheet was used on

casting crucible. The moistened asbestos sheet provides a
clean and good surface on which the alloy could be melted.

 Advantages is, prevent alloy contamination with oxides

and residuals that may be present in the crucible.
 Carbon crucibles can be used not only for high noble crown
and bridge alloys but also for the higher-fusing gold-based
metal-ceramic alloys.

 Carbon crucibles should not be used in melting of high

palladium, palladium silver alloys (to be melted above
1504⁰c) and also with nickel chromium/cobalt
chromium base metal alloys
 Clay crucibles are appropriate for
many of the crown and bridge
alloys, such as the high noble and
noble types.

 Crucibles made from alumina,

quartz, or silica are recommended
for high-fusing alloys of any type.
These are especially suited for
alloys that have a high melting
temperature or those that are
sensitive to carbon contamination.
Casting force
 Casting force > surface tension of alloy + resistance offered by
gas in the mold .

 This can be done by use of following different type of force:

 Vacuum force
 Air or Gas Pressure
 Centrifugal force

 Sufficient mass of alloy must be present to sustain adequate

casting pressure
 6g is typically adequate for premolar and anterior casting
 10g is adequate for molar casting
 12 g is adequate for pontic
 Cleaning the casting

Quenching
 When a type III or IV gold alloy has been cast and it has
solidified, the ring should be quenched in water as soon as
the button exhibits a dull-red glow.
 Two advantages are gained in quenching:

a) The noble metal alloy is left in an annealed condition for

burnishing, polishing, and similar procedures .

b) When the water contacts the hot investment, a violent

reaction ensues, resulting in a soft, granular investment that
is easily removed.
Divesting:

•Removal of Investment /
Recovery of Casting.

•Hold the end of the ring

for about ¼ inch.

• Bulk – finger pressure.

•Sprue is removed from

the restoration using a
carborundum separating
disk/ abrasive disk
mounted in a hand piece.
Pickling
 Surface of the casting appears dark with oxides and tarnish.
Such a surface film can be removed by a process called
pickling.

Solutions used:
 50% HCl
 Phosphoric acid,
 Hydrofluoric acid
 Advantages of HCl: Aids in removal of residual investment
as well as oxide coating.
 Disadvantages: Likely to corrode laboratory metal
furnishings and fumes are health hazard
 Method of cleaning :
a) Place the casting in test tube or dish and pour acid over it.
b) Heating the casting and then dropping into the pickling
solution.

 Gold and palladium based metal ceramic alloys and base

metals, these alloys are not generally pickled if they are
bench cooled.

 Pickling solution should be renewed frequently, since it is

likely to become contaminated.

 Precious alloys(Gold-Platinum-Palladium) can be

soaked with hydroflouric acid .
 Nickel Chromium should never be placed in acid because of
high reactivity.

 Ultrasonic devices are useful for cleaning the casting, as are

commercial pickling solutions made of acid salts. Abrasive
blasting devices are also useful for cleaning the surface of
castings.

 In no case should the casting be held with steel tongs so

that both the casting and the tongs come into contact with
the pickling solution, because this may contaminate the
casting.
 Recovery and cleaning of the casting are more difficult when
a phosphate-bonded investment is used because such
materials do not contain the soft gypsum products.

 Also, the particles usually include large grains of quartz.

 In some instances, such as with gold-containing alloys, the

investment adheres rather tenaciously, usually requiring
cleaning in an ultrasonic device.

 Neither the phosphate binder nor the silica refractory is

soluble in HCl or H2SO4.
Sand blasting :

 Casting is held in a sand blasting machine to clean the

investment from the surface.

 Base metal alloys require a light sandblasting, usually with

fine alumina.

 Chromium-based partial dentures are usually sandblasted to

remove the investment. Acid should not be used for
cleaning base metal alloys
Finishing and polishing :

 Brown or White Al2O3 stones are used.

 Rag or felt wheels impregnated with abrasives are used in

the initial phase of this stage.

 Final polishing is achieved using various oxides of tin and

aluminium used in conjunction with a small rag or chamois
buffing wheel, followed with an iron oxide rouge.

 Residual traces of rosin or waxlike matrix from oxides

 Polishing compound remover followed by a hot, soapy water

rinse.
 References

1. Anusavice K.J.-“Phillips’ Science of Dental

materials” 11th edition , 2003.Pg 319-335.

2. Contemporary fixed prosthodontics

rosenstiel,land , fujimoto- 5 th edition , Pg 601- 618.

3. Removable partial prosthodontics , Mc Cracken’s, 13th

edition, Pg 259 to 265.