CASTING: casting is the process by which the wax pattern of a restoration is converted to a replicate in a dental alloy. The casting process is used to make dental restorations such as inlays, onlays, crowns, bridges and removable partial dentures.

Objectives of casting

1) To heat the alloy as quickly as possible to a completely molten condition.
2) To prevent oxidation by heating the metal with awell adjusted torch .
3) To produce a casting with sharp details by having adequate pressure to the well melted metal to force into the mold.

STEPS IN MAKING A CAST RESTORATION
1. TOOTH PREPARATION
2. IMPRESSION
3. DIE PREPARATION
4. WAX PATTERN FABRICATION
5. SPRUING

Properties of Acrylic Resins.

• They have a low thermal conductivity. These resins are not easily washed out by the acids of the oral cavity (low solubility). Acrylic resins are also resilient, which allows them to be used in stress-bearing areas.
• Acrylic resins exhibit a moderate shrinkage of from 3 to 8 percent. This shrinkage and low marginal strength can lead to marginal leakage. Acrylic resins have a low resistance to wear. Acrylic resins cannot be used over a zinc oxide and eugenol-type base because eugenol interferes with the acrylic curing process.
• Mixing. Insufficient mixing will cause an uneven color or streaks in the mixture. Overmixing will cause the material to harden before it can be placed
• Poor distortion resistance at higher temperatures, therefore dentures should not be cleaned in hot water
• Good resistance to color change
• Absorbs water and must be kept hydrated  (stored in water when not in mouth) to prevent dehydration cycling and changes in dimensions
• Not resistant to strong oxidizing agents
• Low strength; however, flexible, with good fatigue resistance
• Poor scratch resistance; clean tissue-bearing surfaces of denture with soft brush and do not use abrasive cleaners

Mercury hygiene

• Do not contact mercury with skin
• Clean up spills to minimize mercury vaporization
• Store mercury or precapsulated products in tight containers
• Only triturate amalgam components-in tightly- sealed capsules
• Use amalgam with covers
• Store spent amalgam under water or fixer in a tightly sealed jar
• Use high vacuum suction during amalgam alloy placement, setting, or removal when mercury may be vaporized
• Polishing amalgams generally causes localized melting of silver-mercury phase with release of mercury vapor, so water cooling and evacuation must be used

Mechanical properties

1.  Resolution of forces

Uniaxial (one-dimensional) forces-compression, tension, and shear

Complex forces-torsion, flexion. And diametral

2. Normalization of forces and deformatations

Stress

 Applied force (or material’s resistance to force) per unit area

Stress-force/area (MN/m²)

Strain

Change in length per unit of length because of force

Strain-(L- L_o)/(L_o); dimensionless units

3. Stress-strain diagrams

Plot of stress (vertical) versus strain (horizontal)

• Allows convenient comparison of materials
• Different curves for compression, tension, and shear
• Curves depend on rate of testing and temperature

4. Analysis of curves

• Elastic behavior
  • Initial response to stress is elastic strain
  • Elastic modulus-slope of first part of curve and represents stiffness of material or the resistance to deformation under force
  • Elastic limit (proportional limit)- stress above which the material no longer behaves totally elastically
  • Yield strength-stress that is an estimate of the elastic limit at 0.002 permanent strain
  • Hardness-value on a relative scale that estimates the elastic limit in terms of a material’s resistance to indentation (Knoop hardness scale, Diamond pyramid, Brinnell, Rockwell hardness scale, Shore A hardness scale, Mohs hardness scale

• Resilience-area under the stress strain curve up to the elastic limit (and it estimates the total elastic energy that can be absorbed before the onset of plastic deformation)

• Elastic and plastic behavior

• Beyond the stress level of the elastic  limit, there is a combination of elastic  and plastic strain
• Ultimate strength-highest stress  reached before fracture; the ultimate compressive strength is greater than the ultimate shear strength and the ultimate tensile strength
• Elongation (percent elongation)- percent change in length up to the point of fracture = strain x 100%

• Brittle materials-<5% elongation at fracture

• Ductile materials->5% elongation  at fracture
• Toughness-area under the stress strain  curve up to the point of fracture (it estimates the total energy absorbed up to fracture)

• Time-dependent behavior

the faster a stress is applied, the more likely a material is to store the energy elastically and not plastically

• Creep-strain relaxation
• Stress relaxation

CRUCIBLE FORMER

It serves as a base for the casting ring during investing .Usually convex in shape.
May be metal , plastic or rubber .
Shape depends on casting machine used .
Modern machines use tall crucible to enable the pattern to be positioned near the end of the casting machine .

I . Procedure for single casting :

A 2.5 mm sprue former is recommended
for molar crowns 2.0 mm for premolars & partial coverage crowns .

II . Procedure for multiple casting :

Each unit is joined to a runner bar .

A single sprue feeds the runner bar

4 . SPRUE FORMER DIRECTION
Sprue Should be directed away from the delicate parts of the pattern
It should not be at right angles to a flat surface .(leads to turbulance  porosity .)
Ideal angulation is 45 degrees .

5 . SPRUE FORMER LENGTH

Depends on the length of 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.

Significance

Short Sprue Length:

The gases cannot be adequately vented to permit the molten alloy to fill the ring completelyleading to Back Pressure Porosity.

Long Sprue Length:

Fracture of investment, as mold will not withstand the impact force of the entering molten alloy.

Top of wax should be adjusted for :

6 mm for gypsum bonded investments .

3 -4 mm for phosphate bonded investments .
TYPES OF SPRUES

I . - Wax . II . Solid

- Plastic . Hollow
- Metal .