Lost Wax Process

The lost wax casting process is widely used as it offers asymmetrical casting withnvery fine details to be manufactured relatively inexpensively. The process involves producing a metal casting using a refractory mould made from a wax replica pattern.
The steps involved in the process or the lost wax casting are:

1 . Create a wax pattern of the missing tooth / rim
2 . Sprue the wax pattern
3 . Invest the wax pattern
4 . Eliminate the wax pattern by burning it (inside the furnace or in hot water). This will create a mould.
5 . Force molten metal into the mould - casting.
6 . Clean the cast.
7 . Remove sprue from the cast
8 . Finish and polish the casting on the die .

The lost-wax technique is so named because a wax pattern of a restoration is invested in a ceramic material, then the pattern is burned out ("lost") to create a space into which molten metal is placed or cast. The entire lost-wax casting process . 

Wax pattern removal:

Sprue former can be used to remove the pattern. If not the pattern is removed with a sharp probe. Then the sprue former is attached to it. The pattern should be removed directly in line with the principle axis of the tooth or the prepared cavity. Any rotation of the pattern will distort it. Hollow sprue pin is advisable because of its greater retention to the pattern.

WETTABILITY
To minimise the irregularities on the investment & the casting a wetting agent can be used .

FUNCTIONS OF A WETTING AGENT

1 . Reduce contact angle between liquid & wax surface .
2 .Remove any oily film left on wax pattern .

Classification

Rigid impression materials

(1) Plaster
(2) Compound
(3) Zinc oxide-eugenol

Flexible hydrocolloid impression materials

(I) Agar-agar (reversible hydrocolloid)
(2) Alginate (irreversible hydrocolloid)

Flexible, elastomeric, or rubber impression materials

(1) Polysulfide rubber (mercaptan rubber)
(2) Silicone rubber (condensation silicone)
(3) Polyether rubber
(4) Polyvinyl siloxane (addition silicone)
 

Components 

a. Fillers added to most to control shrinkage
b. Matrix

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

PHYSICAL PROPERTIES OF MATERIALS

Definite and precise terms are used to describe the physical properties of dental materials.

a. Hardness. Hardness is the measure of the resistance of a metal to indentation or scratching. It is an indication of the strength and wearability of an alloy or metal.

b. Ductility. Ductility is the measure of the capacity of a metal to be stretched or drawn by a pulling or tensile force without fracturing. This property permits a metal to be drawn into a thin wire.

c. Malleability. Malleability is the measure of the capacity of a metal to be extended in all directions by a compressive force, such as rolling or hammering. This property permits a metal to be shaped into a thin sheet or plate.

d. Flexibility and Elasticity. These terms differ in their technical definition but they are very closely related. Flexibility is the characteristic of a metal, which allows it to deform temporarily. The elasticity of a metal is used when it returns to its original shape when the load or force is removed.

e. Fatigue. Fatigue is the property of a metal to tire and to fracture after repeated stressing at loads below its proportional limit.

f. Structure (Crystalline or Grain Structure). Metals are crystalline and many of their physical properties depend largely upon the size and arrangement of their minute crystals called grains.

(1) Grain size. The size of the grains in a solidified metal depends upon the number of nuclei of crystallization present and the rate of crystal growth. In the practical sense, the faster a molten is cooled to solidification, the greater will be the number of nuclei and the smaller will be the grain size. Generally speaking, small grains arranged in an orderly fashion give the most desirable properties.

(2) Grain shape. The shape of the grains is also formed at the time of crystallization. If the metal is poured or forced into a mold before cooling, the grains will be in a flattened state. Metal formed by this method is known as cast metal. If the metal is shaped by rolling, bending, or twisting, the grains are elongated and the metal becomes a wrought wire.

g. Crushing Strength. Crushing strength is the amount of resistance of a material to fracture under compression.

h. Thermal Conductivity. Thermal conductivity is defined as the ability of a material to transmit heat or cold. A low thermal conductivity is desired in restorative materials used on the tooth whereas a high thermal conductivity is desirable where the material covers soft tissue.