Prosthodontics lab - casting

In this lab we will continue the demonstration for metal framework cobalt-
chromium fabrication .
we know from metal framework cobalt - chromium fabrication that we went in
several steps. we said that 2 basic concepts , there are 2 lost wax processes the
first one for metal fabrication and the second lost wax process for the acrylic so
we want to add the acryl to the partial denture.
in order to do this we made the primary impression and we end with a primary
cast on the primary cast we did initial diagnostic survey to determine where to do
the tooth preparation which include rest preparation , guide plate and contour
modification and we apply the tooth preparation on patient mouth then we took
the secondary impression with custom tray and we pour the secondary cast .
the difference between the secondary cast and the primary cast is there is a guide
plan and there are rest preparations in teeth as we design them,after that we do
the second survey to make sure that what initial design is there in the cast then
we can do block out and relief.
we did two thing in last two weeks in the first step in the master cast we place the
block out and relief for both cast ( maxillary and mandible) the basic idea is what
we try to create space where we do not want metal to go .
the purpose for block out and relief to prevent the metal to go to specific area or
to determine where the metal should go and we do not want to place too much
block out or too little block out .
too much block out loose the denture
too little block out under cut where the metal can go inside
so we need to duplicate this into material which we can use for a lost wax process
we said we duplicated it using either addition silicone or agar - agar and we
duplicate it in investment material .
the basic component of investment material is silica it endure high temprature .
- stone will start decomposing or deteriorating at 150 c.
- investment can withstand temperatures up to 1500 and maybe it stands
more than this temperature depending the type of investment that we use
.
there are two advantages of the duplication :
1- replacing it with the material which can stand the temperature of metal .
2- we're taking the advantage of duplication to add material in the area where we
want to block out .
*we duplicate the stone and the wax in one material .
We have three types of block out :
1- parallel
2- shaped
3- arbitrary
and then we have a relief which will provide us with internal finish line and the
area where the acrylic is going to go.




We said unlike complete denture we can not make two parts mold which we can
separate later.
For metal I have to create an enclosed mold ,so what we're going to do on this
refractory cast is create a wax pattern , the metal can not go to the under cut
What is the difference between secondary cast and refractory cast ?
Refractory made of investment and on this cast we ready to make metal
Secondary made of stone & on this cast we do block out
because we block it out , the metal can not touch the edentulous ridge because
there is a block out underneath it .
- How do we make the mold ?
We can not make a mold which is open and close so we need a sprue , what we
need to do is to create a channel to allowed the wax to go out and for the metal
to go in so we add the channels we use pre-fabricated sprue wax, there is a
different diameter of sprue wax depending on how thick the mold is (Ex: 2.5mm ,
3 mm ).

the channel is attached to bulbous part of the wax pattern in the corners and they
meet together in funnel shape.
every thing which is wax and plastic will become space later on.
we cover all of this with investment then we put it in oven (Furnace) not in boiling
water and what happen is the wax will melt ,then it actually Evaporates and goes
back to the original components then comes out and left with empty mold , the
empty mold will have a shape of the sprues and the wax pattern while it's hot we
take it out from furnace and we put it in other machine called the casting machine
in the casting machine; part of machine will melt the metal and depending on the
type of machine either by vacuum force or by Centrifugal force the metal will go
inside the mold and fill up all the details inside the mold then the metal will cool
down and when it cools down we will break away the mold which is disposable
and inside we will find the metal pattern ,the sprue and the sprue former and we
clean away this investment and we will end up with something a bit cleaner we
notice it looks dark because it's oxidized ( At high temperatures the metal is
oxidized significantly and when we finish and polish it later its going to take a
high shine).
there is a final step where we put it in a Special Electropolisher (Polishing device
contains an electric circuit with acid to polish the metal , This acid works to
remove a very thin layer of metal surface)
investing
the doctor said that we must know the Properties of investment , the wax , the
metal and the stone when stone sets the stone will expand because its
exothermic reaction and it is expanded so the partial denture which is located on
the cast will expand also ( very small amount of expand).
when we duplicated into the refractory model ,the refractory is made of
investment , the investment expand due to expand of stone but in small amount,
the investment is design to expand because when we invest it something going to
happen in the furnace and something is going to happen to the metal when we
melt the metal and the metals cools down inside the mold the metal will contract
so the investment specifically design to counter the contraction of the metal If the
investment does not expand and we put the metal inside the mold when the
metals cools down it will be going smaller than the patient's mouth it won't fit so
the investment must be expand to make a balance between the metal and the
investment.
there are several type of investment , the basic component of the most of them is
pure sand or silica we use it as a mold because it endure a high temperature .
the problem in dentistry is we have very fine details if we made this wax pattern
just put sand on it when we melt the wax ,the sand is going to collapse so we
need something that after we shape the sand, hold the sand together so the thing
which distinguishes between different investment is the binder there is several
type of bonded investment the first type of bonding is sulphatebonded
investment it is the simplest one we mixing the investment with plaster the
problem in this material it doesn't stand high temperature because it made of
calcium sulphateit stand temperature upto 700C this material is good for high
noble with alot of gold in it but if we are going to use a base metal like cobalt
chromium if we try raise the temperature above 700C we are going to end up
with a break down the investment so we need a stronger binder what we uses is a
phosphate bonded investment it is not just phosphate it is a chemical reaction
between two material so that we actually bind the material much higher this type
of investment stand temperatures up to 1000 1100 there is another type of
investment which is called silica bonded investment this type good for cobalt -
chromium and nickel- chromium and there is a type which endure a very high
temperature called titanium alloy (1600c) this material have much higher casting
temperature , each type of these investment has different type of expansion we
can get the expansion in more than one way.
Investment expansion
there is several type of expansion , we have setting expansion from setting
reaction like calcium sulphate ( when calcium sulphate start reacted it is form a
crystal, as a calcium sulphate Precipitates out of solution they form a crystal ,the
extensions will start pushing other crystals apart so it causing over all expansion )
the setting expansion is similar to this when the investment react with each other
we have over all expansion of the investment so just the normal chemical reaction
it called setting expansion but it is not enough.
The second expansion is something only available in sulphate bonded
investment it is called hygroscopic expansion the expansion here occur due to
put the gypsumin water when it initially set . another type of expansion is thermal
expansion and this is the main type of expansion in all investment they are
designed so when we heat this mold is going to become larger so if we have
contraction of metal 1.5% we have expansion 1.5% in the investment
in phosphate bonded investment we have thermal and setting expansion .


During the setting reaction of materials like gypsum, initially the
Precipitates of molecules causes initial contraction, but when the reaction
ends crystals get bigger and it will cause over all expansion.

how we invest ?
We make a sprues so we have a container ,at the bottom we have a cast and we
have wax on the top of it
First we add sprues and then we add sprue former, now we are going to pure
investment material all around which will cover everything.
See the picture below


Now the metal is going inside, whats the part that will cool down first ?
To understand that we must know that if we want to set the metal in the mold,
the mold must be hot, Because if the mold is cold the metal will cool down before
going inside, so at first we put the mold in oven at 950c - 1050c (1000c)then we
heat the metal at 1300C .
the casting temperature is 1000c.
the liquefied temperature is 1300c.
*the higher the temperature the more contraction will happen after it cools down
So first we melt the metal and pour it in the mold then it will start to cool down,
what will cool first ? the first thing that will cool of the metal is the sprue(its
called button because it looks like button )if the sprue cools down first it will start
to solidifies and will pull anything liquid so it will pull the liquid from the pattern
and it will cause distortion of the metal and sometimes it pulls the metal outside
the pattern so fast and it leaves holes in the metal and these holes are called
porosity, one of the reasons for porosity in metal casting is that the metal shrink
so fast and the pattern was the last thing to remain liquid so it is called suck back
porosity and this is very bad because we distort the pattern.
How can we avoid this problem?
what we want to do is to play with the cooling pattern or in thermal central so
first we determine where is the hottest part of the mold ? the hottest part of the
mold is geometric center of the mold and we call it thermo center so because
thermo center is the last thing to cool down ,it is not good for the wax pattern to
be near it or remain liquid the most important thing is the pattern, we do not care
what happens to the sprue , we dont want to distort the pattern so we need to
keep the pattern away from the thermo center, we need to make the funnel and
the sprue long enough to keep the wax pattern away from thermo center also we
must protect it from the sides so we have enough thickness ( at least 6 mm of
investment around the wax pattern in every dimension)
we can do something else which called reservoir (See the picture below)


We will add a big bulge of wax between the funnel and the sprues which will
make a big bulge of metal in the middle, so the top cools first then it cools down,
that mean we use more metal but we protect our casting .
The End
Sorry for any mistake
Done by :Oryb Al-Rabadi
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