TROUBLESHOOTING GUIDE

ALLOYS SOLDERING INVESTMENT PORCELAIN

THE ARGEN CORPORATION

ALLOYS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. SOLDERING 1. 2. 3. 4. 5. 6. INVESTMENT 1. 2. 3. 4. 5. PORCELAIN 1. 2. 3. 4. 5. 6. 7. 8. CHARTS

TABLE OF CONTENTS

PAGE

Porosity.1-2 Brittle Castings. 2-3 Hot Tears 3 Rough Casting 3-4 Suckback 4 Rounded Margins. 4 Incomplete Castings 5 Pattern Failed to Cast5 Pits in Casting5-6 Bubbles or Nodules on Casting 6 Investment Particles in Casting 6 Inconsistent Oxide Appearance6 Warpage7-8 Allow Tarnishing 8-9

Solder Fails to Flow. 9-11 Accidental Melting of Parent Metal. 11 Fractured Soldered Connection.... 11-12 Solder Joint Sag12 Solder Joint Contaminated12 Warpage During Soldering Procedure 13

Investment Sets too Rapidly.13 Investment Sets too Slowly 14 Inconsistent Thickness of Mix 14 Investment Mold Cracks During Burnout 14-15 15 Too Much or Too Little Expansion

Bubbling of Opaque 15-16 17 Cracks in Opaque Porcelain Bubbles 17 Checks, Cracks and Crazing 17-18 Discoloration 18-19 Milky or Chalky Appearance19 Insufficient Glaze 19 Porcelain Bond Failure. 19-20

Temperature Conversion Table (F) (C) DWT - Gram - OZ Conversion

ALLOY TROUBLESHOOTING PROBLEM 1. POROSITY a. Gasses Trapped In Mold Provide a maximum of 1/4 of investment over pattern and minimum 1/4" from sides of ring. If necessary, the height of the sprue former may be adjusted to position wax pattern to proper height. Remove the glaze on the top of the ring to create a porous surface on the investment to allow gas to escape. SOLUTION

b. Insufficient Sprue

The indirect method of spruing is recommended for both single and multiple units. 1) 8 - 10 gauge ingate (from runner bar to pattern) sprues with an approximate length between 2mm and 4mm should be used, depending on pattern size. 2) 4 - 6 gauge runner bars should span the length of bridge. If runner bar conforms to arch shape, relieve stress by cutting and reconnecting in sections. 3) Connect 8 - 10 gauge feeder sprues to bottom of runner bar long enough to allow placement of runner bar in the heat center of the ring. Note: Position the runner bar in the heat center of the ring, and wax patterns outside the heat center. The runner bar will serve as the reservoir supplying molten alloy to castings allowing proper order of solidification to take place. If the direct spruing method is utilized, connect an 8-10 gauge sprue to the thickest portion of the wax pattern. Pontics and larger units may require (2) 8-gauge sprues. Reservoirs are placed 1.5mm (1/16) from the wax pattern.

c. Overheated Mold

Calibrate burnout furnace. Elevated temperatures can interfere with alloy solidification and cooling, affecting casting density. Follow alloys recommended burnout temperature. If mold burnout temperature is too low, the pattern (especially plastic), may not burn out completely. Overheating increases gas inclusions, carbon absorption and oxidation of low melting temperature alloy components.

d. Under Heated Mold

e. Overheated Alloy

1 of 20

PROBLEM f. Wax Contains Dirt

SOLUTION If the wax is noticeably dirty, change the wax in the wax pot. Foreign debris will not burn out and will become incorporated in the casting. Ensure that casting arm is balanced.

g. Turbulence 2. BRITTLE CASTINGS a. Overheating Alloy When Casting

An alloys physical properties will change (especially high palladium alloys) when overheated. Follow alloy manufacturers instruction for proper propane or gas/oxygen ratios to achieve proper flame and proper appearance of alloy when ready to cast.

b. Failure To Add New Alloy To Existing Sprues, Buttons, Etc.

When recasting alloy buttons, 30% - 50% new alloy must be added to restore the original physical properties of that alloy. All alloys must be absolutely clean i.e.: free of investment, oil, blasting materials. Overheated molds may increase grain growth during cooling, thereby increasing the chance for hot tearing and brittleness. Use the alloys recommended burnout temperature. Contamination may change the physical properties of an alloy. Avoid cross contamination by using crucibles, stones, and burs on one alloy only. Cross contamination will cause alloy and porcelain to react in an unpredictable manner. Be careful not to quench the alloy too soon after casting. You may only quench crown & bridge gold alloys. Never quench ceramic alloys.

c. Overheated Mold

d. Alloy Contamination

e. Quenching Too Soon After Casting

2 of 20

PROBLEM f. Carbon Inclusion

SOLUTION Adjust fuel mixtures to proper flame (See page 2 #2-a ). Carbon is major cause of brittleness. Carbon contributors include investment, incomplete wax elimination, improper torch adjustment (especially gas rich flames). Palladium based alloys are particularly sensitive to carbon. Non-carbon investments are recommended for these alloys. Carbon inclusion also increases the risk of porcelain bubbling which may be the first sign that carbon exists in the casting .

3. HOT TEARS a. Brittle Castings b. Quick Stops See page 2 - #2 Never manually stop casting machine from spinning. Natural slowing maintains centrifugal pressure, resulting in proper grain growth. Grain size is directly implicated in hot tearing; some alloys will tear more easily when large grains form. Quenching is not recommended for ceramic alloys. See page 2 #2-C When casting existing buttons, sprues, etc., 30% - 50% new alloy must be added to restore the physical properties of the alloy. This is especially true of ceramic alloys.

c. Quenching d. Overheated Mold e. No New Alloy Added To Existing Buttons When Recasting

4. ROUGH CASTING a. Wax Pattern Cleaner Not Dry Remove all excess wax pattern cleaner with a gentle stream of air. Wax pattern and sprue former base must be totally dry prior to investing. Calibrate burnout oven and use recommended burnout temperature for alloy being cast. Overheated mold may cause investment breakdown. Allow investment to bench set thoroughly before starting burnout procedure. Outdated investment may break down during the burnout procedure. Check expiration date. Overheated alloy during melting may cause investment breakdown.

b. Overheated Mold

c. Investment Not Completely Set

d. Outdated Investment

e. Overheated Alloy

3 of 20

PROBLEM f. Excessive Casting Force

SOLUTION Use of too much casting force may cause rough castings. The recommended amount of turns on your centrifugal casting machine is the following: 2 - 3 turns High Noble: 3 turns Noble: Predominately Base: 4 turns

g. Solid Plastic Sprues

Solid plastic sprues cause excessive pressure in mold when plastic expands during burnout. If plastic sprues are required coat plastic sprues with wax before investing. Oily die lubricant on pattern creating surface tension. Use minimal vibration during investing.

h. Die Lubricant i. Excessive Vibration 5. SUCKBACK a. Overheated Alloy

Properly adjust torch flame ( see page 2 - #2-a ) and melting time to reduce casting temperature of alloy. Wax pattern should be weighed prior to investing by using the following formula; wax pattern x density = alloy amounts . By using this formula, casting buttons will be kept to a minimum.

b. Over Generous Button

c. Spruing 6. ROUNDED MARGINS a. Under Heated Alloy

Utilize the indirect sprue technique.

Metal must be fluid and approximately 150-175 F (66-79C) above the melting range when cast. Check alloy manufactures recommendations for proper casting temperatures.

b. Under Heated Mold

Utilize alloys recommended burnout temperature. An under heated mold will cause alloy to solidify prematurely. See page 1 #1-a

c. Gasses Trapped In Mold

4 of 20

PROBLEM d. Improper Placement Of Ring In Cradle

SOLUTION Trailing edge casting techniques must be followed. Ring should be placed so that the trailing edge (margins) of the wax pattern face the opposite direction of the rotation of the arm of the casting machine. This insures the flow of molten alloy toward the trailing edges preventing miscasts.

7. INCOMPLETE CASTINGS a. Insufficient Burnout Check oven calibration. Always provide a minimum 1 hour heat soak. Add 10 minutes for each additional ring in the oven. See page 1 #1-b An average thickness of at least 0.3 0.4 mm must be maintained to achieve a complete casting. Utilize a wax gauge when in doubt.

b. Spruing Technique c. Insufficient Thickness Of Wax/Plastic Patterns

d. Insufficient Casting Force

Check centrifugal casting arm spring. Give extra wind for low density alloys. Check balance. Turbulence may slow alloy entry into the casting ring. See page 4 #6-a See page 1 #1-a Weigh wax pattern and sprues (as described in page 4 #5b) to determine adequate amount of alloy required to achieve a complete casting.

e. Under Heated Alloy f. Gasses Trapped In Mold g. Improper Amount Of Alloy Used

8. PATTERN FAILED TO CAST a. Pattern Separated From Sprue During Investing (Floaters) 9. PITS IN CASTING a. Overheated Mold Check alloys recommended burnout temperature. A temperature that is too high will cause the alloy to improperly solidify. Reinforce pattern and sprue with a drop of sticky wax. Avoid vigorous vibration during investing procedure.

b. Investment Particles In Castings

See page 6 #11- a,b,c,d

5 of 20

PROBLEM c. Dirty Wax

SOLUTION Place a cover on your wax pot when not in use to avoid getting dust, metal, grindings, etc. in the wax. These do not burn out with the wax. Avoid any grinding (finishing) in waxing area of laboratory. See page 1 #1-e Each piece of used alloy should be examined and cleaned. Insure all investment has been removed prior to remelting.

d. Overheated Alloy e. Excess Investment And Debris Exist On Buttons 10. BUBBLES OR NODULES ON CASTING a. Investment Was Poured Too Fast

Pour the investment into the ring slowly (do not dump it on the wax pattern) to avoid entrapment of air pockets. Apply Wax Pattern Cleaner (debubblizer) and completely blow dry pattern surface and sprue former base with a gentle stream off air prior to investing. Too much vibration may create bubbles while pouring investment.

b. Surface Tension Reducer Was Not Used On Wax Pattern

c. Excessive Vibration During Investing Procedure d. Die Lubricant e. Tiny, Perfectly Round Nodules (May Look Like Retention Beads)

Excessive oil from die separator on pattern. Extend mixing time to 15 sec. under full vacuum without paddle turning. This will allow the gases that form by mixing special liquid with the investment, to be vacuumed out of the mix. Check vacuum mixer to ensure full vacuum is being drawn.

f. Vacuum Insufficient Or Absent 11. INVESTMENT PARTICLES IN CASTING a. Sharp 90% Edges And Corners At Sprue / Wax Pattern Junction

Attach sprues to wax pattern with flared edges. During casting sharp corners may flake off with the force of the molten metal shooting into the casting ring (mold). Avoid any scraping around the sprue hole leads. If the investment surface is scraped initial set up, a rough surface is created on the investment producing, in turn loose particles that may mix in wit molten metal. Also, wait 30 minutes before removing sprue former from newly invested ring. Be certain that investment rings are thoroughly cleaned prior to adding newly mixed investment.

b. Sprue Hole And/Or Sprue Base Has A Roughened Surface

c. Remnants Of Previously Mixed Investment Was Left In Casting Ring

6 of 20

PROBLEM

SOLUTION

d. Burnout Temperature Too High

Assure that burn out temperature does not exceed the maximum temperature allowed by investment manufacturer.

12. INCONSISTENT OXIDE APPEARANCE (AFTER DEGASSING) a. Contaminated Stones Do not cross contaminate finishing stones. Keep stones separated for different alloys. Handle finished casting with tweezers only during blasting and following cleaning and oxidation cycles. Oil from finger tips may easily be transferred to metal surface. These oils will not always burn off during oxidation cycles and will cause patchy appearance or unusual oxide color. Always use the recommended oxidation (degassing) cycle for the alloy. Different alloys (even those with similar composition) may oxidize very differently. Not following the recommended cycle may increase the risk of porcelain discoloration and/or greening. Technique changes may also decrease porcelain-to-metal bond strength. Acids will deplete the minor compositional elements near the surface that are responsible for the oxide. Longer oxidation cycles (rather than higher temperature treatments) will usually replace these elements and form the proper oxide color. Failure to obtain the proper oxide may decrease bond strength. After using acid rinse thoroughly, dry, refinish surface with recommended stones, clean ultrasonically, and then proceed with oxidation (degassing) cycle. See page 2 #2-b

b. Oil Or Debris On Alloy

c. Long Or Short Oxidation Cycle

d. Acid Treatment

e. Recast Alloy 13. WARPAGE (MULTI-UNIT BRIDGES) a. Removing Wax-Pattern Without Reseating It

The wax pattern must not remain off the dies for any extended length of time (especially in warm, humid climates). A time period of no longer than 20 minutes should pass between final wax adjustments to investing. Replace the wax pattern on the die to insure against any problems with the memory of the wax.

7 of 20

PROBLEM

SOLUTION

b. Utilize A Secure (Non Rocking) Double Pin System For Model Work

Be certain that the individual sectioned dies are secure and non rocking. If the dies are easily removable from the model with your fingers, chances are the dies are not adequately secure in the base. You should be forced to loosen the dies by pressing the pin underneath the model (fig A), then remove the dies manually with your fingers (fig B).

Figure A

Figure B

c. Failing To Section Bridge Before Spruing

Before spruing, let the bridge cool down on the model. Next, using wax separating filament or nylon fishing line, cut one joint to every 4 units to relax the inherent stresses of the wax. Then reattach the bridge as desired using dead soft wax. If necessary, use a survey to determine the location of all undesirable undercuts on the die. Be certain that interproximal connectors of multiple unit splints are of adequate thickness strength is derived from the incisogingival dimension. When using wax pots to melt your wax, the daily heating and cooling of wax in the pot will exhaust the properties of the wax, which allows wax to maintain its accuracy. Replace the wax in the pot with new wax approximately once every month. Avoid warpage in vacuum porcelain furnace by using adequate support when ever possible. Support all abutments with firing pins during firing.

d. Undercuts Not Blocked Out Properly

e. Interproximal ConnectorsToo Thin

f. Wax Properties Exhausted

g. Inadequate Support

14. ALLOY TARNISHING a. Porosity Microscopic surface porosity may not only entrap finishing materials but also food particles. This will produce bacteria intraorally which will oxidize the castings surface causing it to discolor. Avoid porosity by using proper spruing techniques. (See page 1 - #1 )

8 of 20

PROBLEM b. Acidity Of Salvia And Certain Medications

SOLUTION Depending on chemical nature of patients physiology, certain medications, where nitroglycerine (heart medication) enzymes are present, may have an influence in tarnishing, as will a high acidity content of the saliva in the oral environment. When high content copper alloys are pickled in hydrochloric acid, the acid should be changed often. A casting that is pickled in copper saturated (green color) acid will transfer that copper to the casting, later causing tarnishing. High levels of sulfur may be present in water (well water) causing a casting to tarnish. The use of two dissimilar metals in the mouth may cause an electrical (galvanic) reaction. Avoid the combination of gold alloys and mercury/amalgam/silver fillings coming in direct contact with each other. SOLDER TROUBLESHOOTING

c. Copper Saturated Acid

d. Sulfur Contamination

e. Galvanic Reaction

1. SOLDER FAILS TO FLOW a. Oxide Build-Up On Parent Metal Certain alloys (especially high palladium content alloys) produce a heavier oxide than others. A heavy oxide on the surfact of the parent metal will act as a deterrent between the solder and the metal, preventing good flow. Lightly flux the area to be soldered with the recommended flux to reduce oxidation and improve solder flow. To avoid oxides from forming on the alloy, do not exceed a temperature of 900F (482C) when preheating invested case in a burnout oven. Extreme caution should be exercised when applying flux to PTM alloys. Utilizing too much flux may cause porcelain contamination. It is possible for solder to produce an oxide prior to soldering which may affect its flow qualities. To avoid this, lightly coat the solder with paste flux. Introduce the solder when the abutment joints exhibit a light yellow/red color. The melting temperature of the parent metal must be higher than the flow point of the solder or flow will not take place. The heat projected from the parent metal is used to melt the solder not the direct heat from the flame. The solder area should have a light yellow/red appearance when ready to accept the solder.

b. Oxidation Of Solder

c. Parent Metal Too Cold

9 of 20

PROBLEM

SOLUTION

d. Rough Solder Joint

It is not necessary to roughen the area to be soldered with stones or cut grooves with a disk to create retention for proper bonding of the solder. It is recommended to utilize a silicone-free rubber wheel. Then, lightly sand blast the joint with 50 micron aluminous oxide with no more than 30 pounds (2 bar) air pressure. A liquid in a slightly etched surface will wet better. Ultrasonically clean in distilled water for 10 minutes. The joining of solder and parent metal does not depend on mechanical retention for a bond, but rather a chemical, metallurgical bond.

e. Solder Gap Too Narrow

The correct space will allow capillary action to occur. Too narrow a solder joint will prevent adequate flow of solder. An average gap of approximately .3mm (business card thickness) is recommended. Both surfaces must be parallel as possible. ( See diagrams below ).

0.25 - 0.75mm

f. Units To Be Soldered Are Covered With Too Much Investment

Investment should be mixed thick enough so that the units do not sink too far into investment mounds. If units to be soldered are covered with too much investment, the flame will be prevented from naturally passing through the area to be soldered, preventing adequate heating and solder flow. Tap water may contain unsuspecting chemicals that may contaminate soldering investment which (in turn) may contaminate the soldering area. Use distilled water to insure purity. Investment patty should be limited to a height of no more than 10 mm to avoid drawing heat from the solder joint. Trim patty with model trimmer accordingly. (See diagram below ).

g. Not Using Distilled Water When Mixing Investment

h. Investment Patty Too Thick

10 of 20

PROBLEM

SOLUTION

2. ACCIDENTAL MELTING OF PARENT METAL DURING SOLDERING a. Incorrect Solder Being Used If the flow of the solder is too close to the melting temperature of the parent alloy, the alloy may begin to distort or melt. It is best to use alloy manufacturers recommended solder for the alloy you are soldering. Avoid overheating of parent alloy by gradually brushing the invested units with the flame in a slow circular motion. Then start concentrating the flame on the area to be soldered. Introduce the heat of the flame from one side. When the parent alloy has been reached a light yellow/red color, introduce the solder from the other side. This process should be completed as quickly as possible without removing the flame from the work.

b. Overheating Of Parent Alloy

3. FRACTURED SOLDER CONNECTION a. Improper Connector Design Design of the solder connectors greatly affects the strength and rigidity of the restoration. Contour the connector so it is as thick as possible incisogingivally. The alloy to be soldered should be as close together and as flat as possible with one another. (See page 10 #1-e) Surface of the parent metal to be soldered must be clean and free of any foreign material. Lightly flux the joint prior to heating. (See page 9 #1-a)

b. Dirt Or Debris In Solder Joint

c. Oxidized Alloy

11 of 20

PROBLEM d. Overheating Of Solder

SOLUTION Overheating the solder by using too hot a flame, or prolonged exposure to flame after solder has flowed, will weaken the solder and produce a porous joint. Once the molten solder has filled the joint, immediately remove the flame directly from the solder joint. Continue to brush the flame over the entire assembly to allow more even cooling of the framework before removing the flame entirely. This technique will allows the assembly to cool more evenly, avoiding less stress. Use the recommended solder for the alloy. Prescribed solders are designed to work the best with the parent metals.

e. Incorrect Solder For Alloy

4. SOLDER JOINT SAG a. Overheating Solder b. Incorrect Solder For Alloy See above, #3-d Melting temperature of solder may be too low for future reheating procedures. Use recommended solder for alloy. Be sure to properly support all abutments, heavy areas and pontics during porcelain firing procedures. Use a porcelain that matures at a lower temperature than the solder being used.

c. Unsupported Bridgework

d. Firing Temperature Of Porcelain Exceeds Melting Point Of Solder 5. SOLDER JOINT CONTAMINATED a. Over Fluxing

When using an excessive amount of flux, the flux may not burn out completely and become trapped in the solder. This will result in a porous joint and cause gassing during porcelain firing procedures. Remove any excess flux that may exist around the soldered joint area by placing it in hydrofluoric acid. Sandblast with non-recycled aluminum oxide, prior to finishing.

b. Improper Use Of Stones, Disks, Etc.

Avoid cross contaminating disks and stones. This will transfer contaminating materials to the surfaces being soldering.

12 of 20

PROBLEM 6. WARPAGE DURING SOLDERING PROCEDURE a. Sectioned Bridge Inaccurately Splinted Together

SOLUTION

A pattern resin with minimal shrinkage properties (i.e.; G.C. Pattern Resin or similar) is recommended to securely bond sectioned parts together. This should be done on a solid (not sectioned) model. Optimum accuracy may be achieved by the dentist doing this chair side in the mouth during a try-in-stage. Always allow restoration to bench cool after soldering. Quenching produces heat shock which may distort the soldered restoration. Once solder has flowed, pull flame back, and lightly brush the flame back and forth over entire bridge to achieve an even temperature. Then pull flame away and allow to bench cool. Accurate fit of a restoration may be affected by shrinkage of excessive amounts of solder. Average gap of a solder joint should be .3mm (business card thickness) to keep solder amount and solder shrinkage to a minimum. (See page 10 #1-e ) INVESTMENT TROUBLESHOOTING

b. Soldered Restoration Was Quenched

c. Soldered Framework Cooled Unevenly

d. Solder Joint Gap Too Wide

1. INVESTMENT SETS TOO RAPIDLY a. Incorrect Liquid/Powder Ratio Check suggested recommendations of proper liquid/powder ratio for investment being used. Spatulate according to investment manufacturers recommended time and speed. Store liquid in a cool location. Ideal liquid temperature is 65 F (18C.) Be certain to clean bowl and blade thoroughly or replace bowl, if necessary. Discard outdated material. Check investment expiration dates.

b. Spatulating Too Long Or Too Fast

c. Room Temperature Too Warm (Above 80 F 27C) a. Presence Of Set Material In Mixing Bowl/On The Mixing Blade e. Aged Investment Powder

13 of 20

PROBLEM 2. INVESTMENT SETS TOO SLOWLY a. Investment Powder And/Or Liquid Is Too Cold

SOLUTION

Do not store powder or liquid in a refrigerator where it will chill liquid too much. Ideal liquid/powder temperature is 65 F (18C) 72F (22C). Avoid contaminants such as alcohol and detergents. Use distilled water only. Use separate mixing bowls for different types of investments. Do not use bowls where gypsum was previously mixed . Increase spatulation time according to investment manufacturers recommendation.

b. Contaminated Mix

c. Insufficient Spatulation

3. INCONSISTENT THICKNESS OF MIX a. Incorrect Liquid/Powder Ratio Check manufactures directions for recommended liquid/powder ratio for investment being used. Measure and weigh accordingly.

b. Investment Powder Exposed To Humidity c. Inconsistent Mix

Store investment powder in a cool, dry place.

If using bulk investment be sure to mix powder before each use. This will insure good particle dispersion.

4. INVESTMENT MOLD CRACKS DURING BURNOUT a. Investment Too Dry When Placed In Oven If ring sets longer than investment manufacturer recommends, soak the ring in water for approximately 5 minutes before placing in a burnout oven. Follow investment technique sheet, or contact manufacturer for specific instructions. Do not overcrowd ring with too many wax patterns. When too much alloy is cast into the ring, excessive weight of molten alloy may create stress to the investment, causing breakdown or cracking of the mold. Do not overwind casting machine. Excessive force of alloy may cause mold to fracture. (See Page 4 #4-f)

b. Too Many Units In Ring

c. Excessive Molten Alloy Force

14 of 20

PROBLEM d. Too Rapid Temperature Climb Of Burnout Oven

SOLUTION If not using a fast fire investment, start with a room temperature oven and raise temperature gradually according to investment manufacturers instructions. Some investments require a slow temperature climb (for example, 10F (-12C) per minute) especially when utilizing the ring less technique. Use a two stage burnout technique. Follow manufacturers instruction for proper liquid/water powder ratio.

e. Incorrect Investment Water/Powder Ratio (Too Much Water May Weaken Investment) f. Plastic Sprues And/Or Patterns

Plastic may require a thin coat of wax to allow for proper expansion. A two-stage burnout is recommended when using plastic sprues and patterns. Allow investment to set up thoroughly before starting burnout procedure. Proper water/powder ratios must be used. If ring liner is used, shake off excess water to prevent change of water powder ratio.

g. Investment Not Completely Set

h. Too Much Moisture In Ring

5. TOO MUCH OR TOO LITTLE EXPANSION a. Improper Setting Expansion Check water/powder ratio investment. Alloys in different categories require different water/powder ratios. To increase and decrease expansion, check the investment manufacturers recommendation. Typical soak time should be 45 minutes to 1 hour for 1 ring at end temperature. Add 10 minutes for each additional ring. PORCELAIN 1. BUBBLING OF OPAQUE a. Overheated Alloy/Opaque b. Insufficient Amount Of New Alloy Verify casting temperature and opaque firing temperature. Incorporate at least 30% new alloy with each melt to restore alloys physical properties.

b. Improper Thermal Expansion

15 of 20

PROBLEM c. Contaminated Alloy

SOLUTION Make certain that burs, stones, points and casting crucibles are not cross contaminated with any other alloy. Do not mix different alloys. Verify whether the alloy being used requires a vacuum hold. Follow alloy manufacturers oxidation instructions. Increase the preheating time. The opaque should be chalk white prior to entering the furnace. Proper drying procedure is critical for paste opaque. Prior to firing paste opaque, do not place framework on oven platform before it reached idle temperature. Follow porcelain firing chart for proper drying times. Make certain no water is mixed in with paste opaque. Paste opaque contains a special liquid. Framework and opaque brushes must be properly dry, free of any moisture. Make certain no excess flux exists in or on the alloy. Some air compressors contain contaminating oils in their air lines that may come in contact with metal surfaces. Oils from fingertips may transfer to metals surface causing contamination. If using 50 micron aluminous oxide, air pressure above 60 psi may cause aluminous oxide particles to become imbedded into the alloy, causing contamination. For high gold PFM alloys, set pressure to 30 psi. High palladium alloys are extremely sensitive to carbon contamination. Do not allow the alloy to come in contact with carbon products, i.e., investment containing carbon, carbon lined casting crucibles, etc. Ultrasonically clean (do not steam clean) in distilled water for 10 minutes. See page 1 #1

d. Incorrect Oxidation Procedure

e. Rapid Preheating Of Powder Opaque f. Rapid Preheating Of Paste Opaque

g. Contaminated Paste Opaque

h. Soldering Flux i. Do Not Blow Dry Metal Surface With Compressed Air j. Handling Metal Surfaces

k. Sandblaster Air Pressure Set Above 60 psi

l. Presence Of Carbon In High Palladium Alloys

m. Metal Not Ultrasonically Cleaned

n. Porosity

16 of 20

PROBLEM 2. CRACKS IN OPAQUE a. Thick Opaque Mix b. Rapid Preheating c. Uneven Thickness

SOLUTION

Apply opaque in a creamy, thin consistency. See page 17 #1-e Apply even layer. Two thin opaque applications are preferable to one thick coat.

3. PORCELAIN BUBBLES a. Inadequate Condensation Body/Dentine b. Dirt And/Or Dust c. Contaminated Liquid Medium d. Improper Burs And Abrasives Apply porcelain without entrapping air. Remove excess moisture.

Ensure that framework and opaque surfaces are clean. Seal all bottles of medium when not in use. Maintain separate non-contaminating abrasives for each alloy. Do not cross contaminate. When finishing porcelain bearing surfaces, it is recommended you grind in one direction only. Do not use high speed or press to hard while grinding. Soft PFM alloys can easily fold over with too much pressure from burrs and stones, trapping air and causing bubbles in opaque and porcelain. Check metal surface for any porosity. See section 1 on opaque bubbling, page 16 #1

e. Improper Metal Preparation

f. Porosity In Metal

4. CHECKS, CRACKS AND CRAZING a. Difference In Coefficient Of Thermal Expansion Between Porcelain And Alloy b. Over Fired, Over Glazed Make sure that alloy and porcelain are compatible with each other. Metal C.T.E. should be slightly higher than porcelain in order to be compatible with each other. Verify furnace calibration and firing cycle. Check oven characteristics by making a porcelain tab (approximately the size of a dime) out of transparent insisal powder. When properly fired, you should be able to read print through it. Observe proper visual indications illustrating proper porcelain maturity.

c. Incorrect Maturity Of Opaque (Under Or Over Fired)

17 of 20

PROBLEM d. Thermal Shock

SOLUTION Avoid cold objects, such as instruments, contacting porcelain while cooling. Some trace elements get burned out of the overheated alloy, changing alloys physical properties. Add 50% new alloy when casting previously casted alloy. In order to restore the original CTE of the alloy, at least 30% 50% new alloy must be added to rejuvenate alloys original physical properties. If this is not done, alloys CTE will likely be altered. Increase preheating time. Porcelain bearing surface should not have sharp angles. Adequate support for porcelain must be designed into the metal substructure. Verify temperature rate of climb. Condense porcelain uniformly. Unfired porcelain will crack if handled too dry. Observe alloy or porcelain manufacturers recommendation for customized cooling. Porcelain should not exceed a thickness of more than 2 mm per unit.

e. Alloy Overheated

f. Failure To Add Adequate Amount Of New Alloy When Casting

g. Rapid Preheating h. Improper Metal Design

i. Rapid Firing Cycle j. Porcelain Worked Too Dry

k. Improper Cooling Procedure

l. Improper Porcelain Support

5. DISCOLORATION a. Contaminated Muffle Purge the muffle according to the furnace manufacturers instructions. Do not cross contaminate crucible and abrasives. Change your hydrofluoric acid regularly. Remove any excess flux from metal surfaces with acid bath after soldering, and before beginning the finishing process. Apply more coats of opaque if necessary.

b. Contaminated Alloy c. Contaminated Acid d. Flux Contamination

e. Thin Opaque Application

18 of 20

PROBLEM f. Over Fired Porcelain

SOLUTION Calibrate furnace and check firing cycle by utilizing a test tab as explained in page 17 # 4-b. Be certain to properly opaque porcelain bearing surfaces. Alloys oxide will bleed through un-opaqued areas, and affect the color of the porcelain once fired.

g. Un-Opaqued Alloy Surface

6. MILKY OR CHALKY APPEARANCE a. Under Fired Opaque b. Improper Temperature Verify proper firing temperature. Check furnace calibration and utilize a test tab as explained in page 17# 4-b. Insure proper level of vacuum is achieved and follow porcelain firing cycle when vacuum should star and be released. Use recommended liquid medium, or distilled water. Do not allow porcelain build up to completely dry.

c. Insufficient Vacuum

d. Wrong Liquid Medium Used e. Rewetting Of Porcelain During Build Up On Substructure 7. INSUFFICIENT GLAZE a. Glaze Temperature Too Low b. False Temperature Reading

Raise temperature and/or hold time of glazing firing cycle. Calibrate your furnace and utilize a porcelain test tab as explained in page 17 #4-b. To obtain a natural glaze, porcelain powders must be brought to full firing maturity during the first bake. If this is not done, a semiglaze will be achieved regardless of how long the firing cycle is. Check with porcelain appearance when full maturity is reached.

c. Under Fired Porcelain

8. PORCELAIN BOND FAILURE a. Difference In Coefficient Of Thermal Expansion Between Porcelain And Alloy b. Underfire Opaque c. Alloy Contamination See page 17 #4-a

See above, #6-a See page 15 #1-c 19 of 20

PROBLEM

SOLUTION

d. Alloy Overheated When Cast

Overheating the alloy during casting will change alloys physical properties. See page 15 #1-b Follow alloy manufacturers recommendation for proper oxidation (degassing) cycle. Improper drying of paste opaque prior to firing will result in an insufficient bond between the ceramics and the alloy surface. Follow porcelain manufactures instructions for recommended drying times, and handling techniques. Change aluminous oxide often or use a non-recycled blasting unit to avoid cross contamination with other alloys.

e. Insufficient Amount Of New Alloy f. Improper Oxidation (Degassing) g. Insufficient Drying Of Paste Opaque

h. Contaminated Aluminous Oxide Used For Sandblasting

20 of 20

CELCIUS/FAHRENHEIT CONVERSION CHART

Locate the temperature you wish to convert in the Reference Column (REF) To find the Fahrenheit equivalent - read to the RIGHT To find the Celsius equivalent - read to the LEFT Example: You are working at 532C. Find 990 in the reference column. Read to the right. Fahrenheit equivalent is 1814

C -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 -11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0.0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9

REF 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75

F 32 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 63.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0

C 24.4 25.0 25.6 26.1 26.7 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 43.0 49.0 54.0 60.0 66.0 71.0 77.0 82.0 88.0 93.0 99.0 100.0 104.0 110.0 116.0 121.0 127.0 132.0 138.0 143.0 149.0 154.0 160.0 166.0 171.0 177.0 182.0 188.0 193.0 199.0 204.0 210.0 216.0 221.0 227.0 232.0 238.0 243.0 249.0 254.0 260.0 266.0 271.0 277.0 282.0 288.0 293.0 299.0 304.0 310.0 316.0

REF 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 110 120 130 140 150 160 170 180 190 200 210 212 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 600

F 168.8 170.6 172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 230.0 248.0 266.0 284.0 302.0 320.0 338.0 356.0 347.0 392.0 410.0 413.6 428.0 446.0 464.0 482.0 500.0 518.0 536.0 554.0 572.0 590.0 608.0 626.0 644.0 662.0 680.0 698.0 716.0 734.0 752.0 770.0 788.0 806.0 824.0 842.0 860.0 878.0 896.0 914.0 932.0 950.0 968.0 986.0 1004.0 1022.0 1040.0 1058.0 1076.0 1094.0 1112.0

C 321 327 332 338 343 349 354 360 366 371 377 382 388 393 399 404 410 416 421 427 432 438 443 449 454 460 466 471 477 482 488 493 499 504 510 516 521 527 532 538 543 549 554 560 566 571 577 582 588 593 599 604 610 616 621 627 632 638 643 649 654 660 666 671 677 682 688 693 699 704 710 716 721 727 732 738

TEMPERATURE CONVERSION TABLE REF F C REF 1130 743 610 1370 1148 749 620 1380 1166 754 630 1390 1184 760 640 1400 1202 766 650 1410 1220 771 660 1420 1238 777 670 1430 1256 782 680 1440 1274 788 690 1450 1292 793 700 1460 1310 799 710 1470 1328 804 720 1480 1346 810 730 1490 1364 816 740 1500 1382 821 750 1510 1400 827 760 1520 1418 832 770 1530 1436 838 780 1540 1454 843 790 1550 1472 849 800 1560 1490 854 810 1570 1508 860 820 1580 1526 866 830 1590 1544 871 840 1600 1562 877 850 1610 1580 882 860 1620 1598 888 870 1630 1616 893 880 1640 1634 899 890 1650 1652 904 900 1660 1670 910 910 1670 1688 916 920 1680 1706 921 930 1690 1724 927 940 1700 1742 932 950 1710 1760 938 960 1720 1778 943 970 1730 1796 949 980 1740 1814 954 990 1750 1832 960 1000 1760 1850 966 1010 1770 1868 971 1020 1780 1886 977 1030 1790 1904 982 1040 1800 1922 988 1050 1810 1940 993 1060 1820 1958 999 1070 1830 1976 1004 1080 1840 1994 1010 1090 1850 2012 1016 1100 1860 2030 1021 1110 1870 2048 1027 1120 1880 2066 1032 1130 1890 2084 1038 1140 1900 2102 1043 1150 1910 2120 1049 1160 1920 2138 1054 1170 1930 2156 1060 1180 1940 2174 1066 1190 1950 2192 1071 1200 1960 2210 1077 1210 1970 2228 1082 1220 1980 2246 1088 1230 1990 2264 1093 1240 2000 2282 1099 1250 2010 2300 1104 1260 2020 2318 1110 1270 2030 2336 1116 1280 2040 2354 1121 1290 2050 2372 1127 1300 2060 2390 1132 1310 2070 2408 1138 1320 2080 2426 1143 1330 2090 2444 1149 1340 2100 2462 1154 1350 2110 2480 1160 1360 2120

F 2498 2516 2534 2552 2570 2588 2606 2624 2642 2660 2678 2696 2714 2732 2750 2768 2786 2804 2822 2840 2858 2876 2894 2912 2930 2948 2966 2984 3002 3020 3038 3056 3074 3092 3110 3128 3146 3164 3182 3200 3218 3236 3254 3272 3290 3308 3326 3344 3362 3380 3398 3416 3434 3452 3470 3488 3506 3524 3542 3560 3578 3596 3614 3632 3650 3668 3686 3704 3722 3740 3758 3776 3794 3812 3830 3848

C 1166 1171 1177 1182 1188 1193 1199 1204 1210 1216 1221 1227 1232 1238 1243 1249 1254 1260 1266 1271 1277 1282 1288 1293 1299 1304 1310 1316 1321 1327 1332 1338 1343 1349 1354 1360 1366 1371 1377 1382 1388 1393 1399 1404 1410 1416 1421 1427 1432 1438 1443 1449 1454 1460 1466 1471 1477 1482 1488 1493 1499 1504 1510 1516 1521 1527 1532 1538 1543 1549 1554 1560 1566 1571 1577 1582

REF 2130 2140 2150 2160 2170 2180 2190 2200 2210 2220 2230 2240 2250 2260 2270 2280 2290 2300 2310 2320 2330 2340 2350 2360 2370 2380 2390 2400 2410 2420 2430 2440 2450 2460 2470 2480 2490 2500 2510 2520 2530 2540 2550 2560 2570 2580 2590 2600 2610 2620 2630 2640 2650 2660 2670 2680 2690 2700 2710 2720 2730 2740 2750 2760 2770 2780 2790 2800 2810 2820 2830 2840 2850 2860 2870 2880

F 3866 3884 3902 3920 3938 3956 3974 3992 4010 4028 4046 4064 4082 4100 4118 4136 4154 4172 4190 4208 4226 4244 4262 4280 4298 4316 4334 4352 4370 4388 4406 4424 4442 4460 4478 4496 4514 4532 4550 4568 4586 4604 4622 4640 4658 4676 4694 4712 4730 4748 4766 4784 4802 4820 4838 4856 4874 4892 4910 4928 4946 4964 4982 5000 5018 5036 5054 5072 5090 5108 5126 5144 5162 5180 5198 5216

C 1588 1593 1599 1604 1610 1616 1621 1627 1632 1638 1643 1649

REF 2890 2900 2910 2920 2930 2940 2950 2960 2970 2980 2990 3000

F 5234 5252 5270 5288 5306 5324 5342 5360 5378 5396 5414 5432

DWT-GRAM-OZ CONVERSION CHART

DWT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

GRAM
1.56 3.11 4.67 6.22 7.78 9.33 10.89 12.44 14 15.55 17.11 18.66 20.22 21.77 23.33 24.88 26.44 27.99 29.55 31.1 32.66 34.21 35.77 37.32 38.88 40.43 41.99 43.54 45.1 46.65

OZ
0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 0.85 0.9 0.95 1 1.05 1.1 1.15 1.2 1.25 1.3 1.35 1.4 1.45 1.5

The Argen Corporation 5855 Oberlin Drive San Diego, CA 92121-4718 United States of America Telephone: (858) 455-7900 Fax: (858) 626-8686 www.argen.com

2007 COPYRIGHT Argen Corporation. All rights reserved. May not be reproduced without permission from Argen Corporation.