CASTING

PROCEDURE
 BURNOUT PROCEDURE

• DONE AFTER 1 HR. IF DELAYED

SHOULD BE STORED IN 100%
HUMIDITY.

• IN CASE OF SILICON RING IS

USED, IT IS REMOVED BEFORE
BURNOUT.
PURPOSE:

• COMPLETE ELIMINATION OF WAX

• CREATE THE MOULD SPACE FOR METAL FLOW

• THERMAL EXPANSION OF THE MOULD.

• TO BRING THE MOULD TEMPERATURE CLOSE

TO MELTING TEMPERATURE OF ALLOY.
PROCEDURE:

• SHOULD BE PLACED IN FURNACE AT ROOM

TEMPERATURE.

• GRADUAL RAISE IN TEMPERATURE.

• FOR GYPSUM INVESTMENT 500 – 700 C;

• FOR PHOSPHATE INVESTMENT 700 – 1030 C.

LOW HEAT TECHNIQUE:

• EXPANSION OCCURS BY
- HYGROSCOPIC EXPANSION OF THE MOULD
- THERMAL EXPANSION OF THE MOULD

• BURNOUT DONE AT 500 C

• TEMPERATURE SHOULD BE MAINTAINED FOR

1HR
ADVANTAGE:
• LESS DEGRADATION OF THE MOULD
• SMOOTH CASTING

DISADVANTAGE:
• RESIDUAL CARBON ENTRAPPED IN MOULD;
CAUSE BACK PRESSURE POROSITY.
HIGH HEAT TECHNIQUE:
• COMPENSATION OF METAL SHRINKAGE IS
BY THERMAL EXPANSION.
• HEATED TO THE TEM OF 700 -1300 C
 CASTING
TECHNIQUE
 CRUCIBLES

• PLATFORM OVER WHICH THE ALLOY IS

PLACED FOR MELTING
• MATERIALS USED
CLAY
CARBON
QUARTZ
• CLAY CRUCIBLES ARE USED WITH HIGH
NOBLE AND NOBLE METAL ALLOYS
• USED FOR CROWN AND BRIDGES.
• QUARTZ CRUCIBLES ARE RECOMMENDED
FOR HIGH-FUSING ALLOYS OF ANY TYPE
OF BASE METAL ALLOYS AND PALLADIUM
ALLOYS
CARBON CRUCIBLES:

FOR HIGH NOBLE CROWN AND BRIDGE AND

ALSO FOR HIGHER FUSING GOLD-BASED
METAL CERAMIC ALLOYS.
CASTING MACHINES
CASTING OF AN ALLOY INTO THE MOLD
SPACE USES 2 BASIC REQUIREMENTS.

A) HEAT SOURCE – TO MELT THE ALLOY

B) CASTING FORCE – TO FORCE MOLTEN

ALLOY INTO MOLD
BASED ON THE METHOD OF MELTING OF
ALLOY
• TORCH FLAME & CENTRIFUGAL CASTING
• INDUCTION HEATING
• RESISTANT HEATING
• ELECTRIC ARC
 CENTRIFUGAL CASTING

ALLOY IS MELTED BY TORCH FLAME HELD

DIRECTLY OVER THE ALLOY.
GAS SOURCE:
• PROPANE AND AIR
• NATURAL GAS & AIR
• ACETYLENE & AIR
• OXYGEN ACETYLENE. (2.5:1)
ZONES OF THE BLOW TORCH FLAME:
• ZONE 1 – MIXING ZONE
• ZONE 2 – COMBUSTION ZONE
• ZONE 3 – REDUCING ZONE
• ZONE 4 – OXIDIZING ZONE
ZONE 1: MIXING ZONE

• PLACE WHERE THE MIXTURE OF AIR AND

GAS OCCURS.

• NO HEAT IS PRESENT AT THIS ZONE

ZONE 2: COMBUSTION ZONE:

• GREEN COLOUR

• GAS AND AIR ARE PARTIALLY BURNT

• OXIDATION OCCURS HERE AND SHOULD

BE KEPT AWAY FROM ALLOY
ZONE 3: REDUCING ZONE

• DIMLY BLUE COLOUR USED TO MELT THE

ALLOY.

• HOTTEST PART OF THE FLAME.

ZONE 4: OXIDISING ZONE:

• COMBUSTION BETWEEN GAS AND

ATMOSPHERE TAKES PLACE.

• SHOULD NOT BE USED TO MELT ALLOY.

• MOLTEN ALLOY IS ENTER THE MOULD BY
CENTRIFUGAL FORCE THAT DEVELOPS
DUE TO ROTATIONAL MOTION OF THE
ARM.
• HYDROSTATIC PRESSURE GRADIENT
DEVELOP ALONG THE LENGTH OF THE
CASTING REACHING ZERO AT THE
BUTTON.
• HENCE HEAT TRANSFER IS ALSO
MAXIMUM AT THE TIP.
• SOLIDIFICATION PROCEEDS FROM THE
THIN MARGIN TO THE BUTTON SURFACE.
 ELECTRIC RESISTANT HEATING
CASTING MACHINE

• CURRENT IS PASSED THROUGH A

RESISTANCE HEATING CONDUCTOR.
• THIS HEATS THE CRUCIBLE AND MELTS
THE ALLOY.
 INDUCTION CASTING MACHINE

• ALTERNATE CURRENT FLOWS THROUGH

THE PRIMARY WINDING COIL AND
CREATES VARIABLE MAGNETIC FIELD.
• THE ALLOY IS MELTED BY AN INDUCTION
FIELD THAT DEVELOPS WITHIN A
CRUCIBLE.
 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.
VACUUM- OR PRESSURE-ASSISTED
CASTING MACHINE

• THE MOLTEN ALLOY IS HEATED TO THE

CASTING TEMPERATURE, DRAWN INTO
THE EVACUATED MOLD BY GRAVITY OR
VACUUM, AND SUBJECTED TO ADDITIONAL
PRESSURE TO FORCE THE ALLOY INTO THE
MOLD.
FLUXING:
• FLUX IS ADDED DURING MELTING OF
GOLD ALLOYS.
• FUSED BORAX POWDER GROUND WITH
BORIC ACID POWDER IS USED.
• ADDED WHEN ALLOY IS MELTED.
ADVANTAGE:
• MINIMISE POROSITY
• INCREASE FLUIDITY OF THE ALLOY
• PREVENTS OXIDATION.
THANK YOU