Effects of sprue design, casting machine, and heat source on casting porosity

Analysis of four dental alloys following torch/centrifugal and induction/ vacuum-pressure casting procedures

STATEMENT OF PROBLEM

Previous studies have shown casting methodology to influence the as-cast properties of dental casting alloys. It is important to consider clinically important mechanical properties so that the influence of casting can be clarified.

PURPOSE

The purpose of this study was to evaluate how torch/centrifugal and inductively cast and vacuum-pressure casting machines may affect the castability, microhardness, chemical composition, and microstructure of 2 high noble, 1 noble, and 1 base metal dental casting alloys.

MATERIAL AND METHODS

Two commonly used methods for casting were selected for comparison: torch/centrifugal casting and inductively heated/ vacuum-pressure casting. One hundred and twenty castability patterns were fabricated and divided into 8 groups. Four groups were torch/centrifugally cast in Olympia (O), Jelenko O (JO), Genesis II (G), and Liberty (L) alloys. Similarly, 4 groups were cast in O, JO, G, and L by an inductively induction/vacuum-pressure casting machine. Each specimen was evaluated for casting completeness to determine a castability value, while porosity was determined by standard x-ray techniques. Each group was metallographically prepared for further evaluation that included chemical composition, Vickers microhardness, and grain analysis of microstructure. Two-way ANOVA was used to determine significant differences among the main effects. Statistically significant effects were examined further with the Tukey HSD procedure for multiple comparisons. Data obtained from the castability experiments were non-normal and the variances were unequal. They were analyzed statistically with the Kruskal-Wallis rank sum test. Significant results were further investigated statistically with the Steel-Dwass method for multiple comparisons (α=.05).

RESULTS

The alloy type had a significant effect on surface microhardness (P<.001). In contrast, the technique used for casting did not affect the microhardness of the test specimen (P=.465). Similarly, the interaction between the alloy and casting technique was not significant (P=.119). A high level of castability (98.5% on average) was achieved overall. The frequency of casting failures as a function of alloy type and casting method was determined. Failure was defined as a castability index score of <100%. Three of 28 possible comparisons between alloy and casting combinations were statistically significant. The results suggested that casting technique affects the castability index of alloys. Radiographic analysis detected large porosities in regions near the edge of the castability pattern and infrequently adjacent to noncast segments. All castings acquired traces of elements found in the casting crucibles. The grain size for each dental casting alloy was generally finer for specimens produced by the induction/vacuum-pressure method. The difference was substantial for JO and L.

CONCLUSIONS

This study demonstrated a relation between casting techniques and some physical properties of metal ceramic casting alloys.

Marginal gap of crowns made with a phosphate-bonded investment and accelerated casting method

STATEMENT OF PROBLEM

Numerous materials and methods have been used for complete crown fabrication. Conventional investing and casting procedures for phosphate-bonded investments require a 2- to 4-hour process before completion. Accelerated laboratory techniques have been used, but may not result in castings with equal marginal accuracy.

PURPOSE

This study measured the marginal gap and determined the clinical acceptability of single castings invested in a phosphate-bonded investment with the use of conventional and accelerated methods.

MATERIAL AND METHODS

Forty-four individual stone casts were poured from impressions made from a master die. Conventional and accelerated methods of investing and casting were followed in the fabrication of 44 single-unit castings. Twenty-two casts were used in each of the 2 groups. Each casting and its respective stone die were examined with a microscope at 4 predetermined sites. Perpendicular and 25-degree tilted measurements of marginal gap were documented for each. Evidence of marginal gap was then evaluated by t test.

RESULTS

Measurements recorded on the perpendicular and on a 25-degree tilt showed no statistically significant difference between conventional and accelerated groups. All gap measurements except one were within the range of clinical acceptability. The measurements revealed that conventional and accelerated perpendicular gap means were 13.2 and 13.6 microm, respectively, and the average tilted gap means were 31.6 and 32.2 microm, respectively.

CONCLUSIONS

A phosphate-bonded investment (Ceramigold) selected for an accelerated casting technique produced single castings within 30 minutes with marginal gaps comparable to those found that used conventional methods.

Sprue design in removable partial denture casting

OBJECTIVES

Correct sprue design is a major factor in the reduction of defects in castings of cobalt-chromium alloy. The purpose of this study was to investigate the sprue arrangements decided by a group of dental technicians, for a series of proposed removable partial denture castings, in order to determine if there was any consistency between them which would suggest the application of criteria in their design.

METHODS

Information was gathered by postal inquiry with recipients asked to indicate their sprue designs on diagrams of patterns for proposed cobalt-chromium partial denture castings.

RESULTS

Replies were received for 260 proposed castings from dental schools, technical colleges and commercial laboratories which gave an overall response rate of 52%. Results displayed a wide range of responses in relation to sprue number and dimension, attachment site and the intended direction of metal flow.

CONCLUSION

It was concluded that the group of technicians studied arbitrarily chose sprue arrangements for the castings proposed rather than following definite design criteria that seek to minimize potential problems during casting procedures.

Comparison of the effects of three sprue designs on the internal porosity in crowns cast with a silver-free high-palladium alloy

This study tested the effect of bsprue design on internal porosity of a silver-frees high-palladium alloy. The designs evaluated consisted of: (1) a cylindrical sprue, (2) a cylindrical sprue with a reservoir, and (3) cylindrical sprue with a constriction at the point of attachment with the pattern. Ten identical complete crowns were made with each sprue design. The cast crowns were embedded in epoxy resin, sectioned, and polished. A total of six sites for each sample were analyzing computer. The mean amount of internal porosity from all analyzed sites for each sprue design was calculated as a percent site porosity per total site and differences between the experimental sites and groups tested. The analysis of variance found no significant differences among the sprues and no significant interaction, but determined a significant difference (p less than 0.05) among the sites analyzed. Tukey's studentized range test showed that the sprue contained a significantly greater percentage of porosity than any of the other sites analyzed.

The effect of sprue attachment design on castability and porosity

Sprue attachment design is an important and controversial variable that can affect casting characteristics of castability and porosity. Four sprue attachment designs--straight, flared, abrupt constriction, and gradual constriction--were investigated. Standardized wax copings simulating complete veneer metal ceramic crowns with knife-edge margins were sculpted on refractory investment dies, sprued, invested, and cast with Olympia alloy. The specimens were embedded, sectioned, and polished. Castability was analyzed by measuring the width of the cast meniscus of the margins. The margin widths of the flared and the straight sprue attachment groups were significantly less than the abrupt or gradual constriction attachment group (p less than 0.05). Photomicrographs revealed discernible differences in the relative quantity and location of porosity in the sprue-coping junctions. The straight and flared sprue attachment groups were less porous than the abrupt or gradual constriction groups (p less than 0.01). Flared and straight sprue attachments optimized castability and minimized porosity.

Construction of a ceramometal mandibular repositioning splint

This article described laboratory and chairside techniques for making a porcelain-bonded-to-metal occlusal overlay repositioning splint and suggests how both dental laboratory technician and dentist can anticipate and overcome some problems commonly encountered during fabrication and seating. A ceramometal occlusal overlay and repositioning splint is often the splint of choice for patients who must wear one at all times during prolonged occlusal splint therapy. Unlike the commonly used acrylic resin splints, the ceramometal splint is durable, provides good esthetics and anatomic functional tooth form, and can be worn at all times including meals.