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.

Corrosion behavior of as-received and previously cast type III gold alloy.

PURPOSE: The rationale for using gold alloys is based largely upon their alleged ability to resist corrosion, but little information is available to determine the corrosion behavior of recast alloys. This study characterized the elemental composition of as-received and recast type III gold alloy and examined the in vitro corrosion behavior in two media using a potentiodynamic polarization technique. MATERIALS AND METHODS: Seventy-eight disk-shaped specimens were prepared from a type III gold alloy under three casting protocols according to the proportion of as-received and recast gold alloy (n = 26). (1) Group as received (100% as-received metal), (2) group 50% to 50% (50% wt. new metal, 50% wt. once recast metal), and (3) group recast (100% once recast metal). The surface structures of 20 specimens from each group were examined under scanning electron microscopy, and their elemental compositions were determined using X-ray energy-dispersive spectroscopy. Further, the potentiodynamic cyclic polarization between -1000 and +1000 mV (SCE) were performed for six specimens from each casting protocol in 0.09% NaCl solution (n = 3) and Fusayama artificial saliva (n = 3) at 37 degrees C. Zero-current potential and corrosion current density were determined. The data were analyzed with 1-way ANOVA and the Ryan-Einot-Gabriel-Welsch multiple-range test t (alpha= 0.05). RESULTS: Elemental composition was significantly different among the casting groups (p < 0.001). The mean weight percentage values were 72.4 to 75.7% Au, 4.5 to 7.0% Pd, 10.7 to 11.1% Ag, 7.8 to 8.4% Cu, and 1.0 to 1.4% Zn. The mean values for Zero-current potential and corrosion current density for all casting protocols were not significant (p > 0.05); however, the difference between the electrolytes was significant (p < 0.001). Fusayama artificial saliva seemed to offer the most corrosive environment. CONCLUSIONS: Type III gold alloy in any casting protocol retained passivity under electrochemical conditions similar to the oral environment. Moreover, high-gold type III alloys from reputable manufacturers and recasting protocol tested should produce acceptable corrosion-resistant castings.

Surface and elemental alterations of dental alloys induced by electro discharge machining (EDM).

OBJECTIVES: To evaluate the surface and elemental alterations induced by electro discharge machining (EDM) on the surface of dental cast alloys used for the fabrication of implant retained meso- and super-structures. METHODS: A completed cast model of an arch that received dental implants was used for the preparation of six wax patterns which were divided into three groups (Au, Co and Ti). The wax patterns of the Au and Co groups were invested with conventional phosphate-bonded silica-based investment material and the Ti group with magnesia-based investment material. The investment rings of the Au and Co groups were cast with an Au-Ag alloy (Stabilor G) and a Co-Cr base alloy (Okta C), respectively, while the investment rings of group Ti were cast with cp Ti (Biotan). One casting of each group was subjected to electro discharge machining (EDM); the other was conventionally ground and polished. The surface morphology and the elemental compositions of conventionally and EDM-finished surfaces were studied by SEM/X-ray EDS analysis. Six spectra were collected from each surface employing the area scan mode and the mean value of each element between conventionally and EDM-finished surfaces was statistically analyzed by t-test (a=0.05). Then the specimens of each group were cut perpendicular to their longitudinal axis and after metallographic grinding and polishing the cross-sections studied under the SEM. RESULTS: The EDM surfaces showed a significant increase in C due to the decomposition of the dielectric fluid during spark erosion. Moreover, a significant Cu uptake was noted on these surfaces from the decomposition of the Cu electrodes used for EDM. Cross-sectional analysis showed that all alloys developed a superficial zone (recast layer) varying from 2 microm for Au-Ag to 10 microm for Co-Cr alloy. SIGNIFICANCE: The elemental composition of dental alloy surfaces is significantly altered after EDM treatment.

Age hardening by dendrite growth in a low-gold dental casting alloy.

Commercial low-gold dental casting alloy composed of Ag-Pd-In-Au-Zn was studied to clarify the age-hardening mechanism and related microstructural changes. The hardness of solution-treated specimen began to increase and reached the maximum value with ageing time, and then the maximum hardness value decreased by further ageing. The changes of X-ray diffraction (XRD) pattern during isothermal ageing revealed that the age hardening was not caused by phase transformation. By comparing the age-hardening curve with the changes in full-width at half-maximum of the XRD peaks at each ageing time, it was revealed that the coherency strains were formed in the Ag-rich matrix, which contributed to the hardness increase during ageing. From scanning electron microscopic observation and electron probe microanalysis, it was clarified that fine particle-like structures composed of InPd containing small amount of Zn gathered by diffusion in the Ag-rich matrix, and the coherency strains which formed during that time caused the hardness increase in the early stage of age-hardening process. The coherency strains were released by the progress of coarsening of Zn-containing InPd dendrite during further ageing, which caused the overaging in the later stage of age-hardening process.

Polarization-corrosion behavior of commercial gold- and silver-base casting alloys in Fusayama solution.

Based on polarization measurements, high Au alloys are highly corrosion-resistant and exhibit the lowest corrosion rates; intermediate Au, Ag, and Pd alloys with Cu are passive but exhibit higher corrosion rates. Twenty weight percent (w/o) In-Ag alloys exhibit active corrosion behavior at potentials only 100 mV noble to the corrosion potential.

Artifacts from dental casting alloys in magnetic resonance imaging.

The potential advantage of magnetic resonance imaging (MRI) has been limited by artifacts due to the presence of metallic materials. For quantitative evaluation of the magnitude of artifacts from dental casting alloys and implant materials in MR imaging, 11 dental casting or implant materials were imaged by means of 1.5 T MRI apparatus with three different sequences. Mean and standard deviation of water signal intensity (SI) around the sample in the region of interest (1200 mm(2)) were determined, and the coefficient of variation was compared for evaluation of the homogeneity of the SI. A variety of artifacts with different magnitudes was observed. Only one of the samples, composed mainly of Pd, In, and Sb, showed no artifacts in all imaging sequences. We concluded that selection of specific dental casting alloys according to their elemental compositions could minimize the metal artifacts in MRI; however, titanium alloys currently pose a problem with respect to causing MRI artifacts.

The release of elements of dental casting alloys into cell-culture medium.

Ten dental casting alloys were tested for alloy-element release into cell-culture medium, and this release was related to alloy composition, alloy microstructure, and alloy cytotoxicity (previously determined). Cell-culture medium was analyzed for alloy elements by flame atomic absorption. Concentrations of elements in the medium were normalized by dividing them by their atomic abundance in the alloy, giving element medium-alloy ratios (EMA ratios). Results showed that Au, In, and Pd generally did not dissolve into the medium, but that Ag, Cd, Cu, Ga, Ni, and Zn frequently dissolved. Comparison of EMA ratios for Ag, Cu, and Zn showed that each element retained a behavioral identity in diverse metallurgical environments, but that these environments influenced the release behavior to some degree. Some EMA ratios in multiphase alloys were greater than those in solid solutions, and EMA ratios showed great diversity within all the alloys. Nominal composition seemed to be of little value in the prediction of metal release unless the composition supported multiple-phase formation. In addition, release of alloy elements did not, in itself, completely predict alloy cytotoxicity measured previously. However, cytotoxicity was associated with metal release in each case. The commercial alloys used in this study exhibited more complex and less predictable release behavior than did the simpler ternary alloy systems used by previous investigators. It is believed that the use of commercial preparations is necessary for their in vivo behavior to be modeled.

The structure of a commercial dental Ag-Pd-Cu-Au casting alloy.

The structure of a commercial dental Ag-Pd-Cu-Au casting alloy has been studied by microprobe and X-ray diffraction analyses after various heat treatments. The composition of phases in equilibrium was established. After being annealed at 400 degrees C, 500 degrees C, and 600 degrees C for seven wk, the alloy consisted of three phases: a Cu- and Pd-rich fee phase (alpha 1) with alpha = 0.372nm, a Ag-rich matrix (alpha 2) with alpha = 0.399nm, and an ordered CsCl-type bcc PdCu phase with alpha = 0.296nm. The PdCu phase was not observed above 600 degrees C, and the proportion of the alpha 1 phase decreased sharply above 700 degrees C. After being annealed at 900 degrees C, the alloy matrix was partly decomposed at the Cu-enriched grain boundaries. The decomposed areas grew into the grain interior during subsequent precipitation hardening. No segregation of Au was detected after casting, and the element was evenly distributed throughout the alloy structure after all heat treatments.

The effects of cleaning on the kinetics of in vitro metal release from dental casting alloys.

The kinetics of the release of elements from six dental casting alloys into cell-culture medium was assessed by means of atomic absorption spectroscopy. Alloys were evaluated in the polished and polished-cleaned conditions so that the effects of cleaning could be determined. Auger scanning microscopy was used for analysis of the surfaces of selected alloys before and after exposure to the cell-culture medium. Release patterns for each element were characterized by the shape of the dissolution vs. time curve, concentration of the element at 12 h as a percentage of the 72-hour concentration, and the relative slope of the curve from 48 to 72 h. Three patterns of release were observed for elements in these alloys. Type I patterns had logarithmic shapes with relatively large 12-hour concentrations and low 48-72-hour slopes. Type II patterns had logarithmic shapes but with moderate 12-hour concentrations and 48-72-hour slopes. Type III patterns were polynomial in shape, had relatively low 12-hour concentrations, and had large 48-72-hour slopes. Cleaning did not change the pattern of release but did generally significantly decrease the quantities of elements released (p = 0.05). The type of dissolution vs. time curve appeared to be dependent upon the element and the composition of the alloy. When cleaning reduced dissolution, surface analyses showed that the cleaning process increased the abundance of elements such as Au and Pd and reduced the abundance of Ag and Cu. Elements which were released from the alloys were more abundant on the surface than in the bulk in both polished and polished-cleaned conditions.(ABSTRACT TRUNCATED AT 250 WORDS)

Toothbrushing causes elemental release from dental casting alloys over extended intervals.

The release of elements from dental alloys has been linked to alloy biocompatibility. Much of the research measuring elemental release has been done in vitro under passive conditions. The current study supplements a previous report that measured elemental release from dental alloys during and after the equivalent of 1 week of toothbrushing. In the current study, toothbrushing times were extended to the equivalent of 2 years, and elemental release was measured during and after brushing, with and without toothpaste. The results showed that for the major classes of dental alloys, brushing alone caused no significant elemental release during the brushing, and only minor increases after brushing. Brushing with toothpaste caused significant increases in elemental release for all elements of all alloys, but the largest increases were for the two nickel-based alloys. Nickel released during brushing with toothpaste reached 600-800 microg/cm(2) of alloy surface. Both beryllium-containing and non-beryllium-containing nickel-based alloys behaved similarly, refuting claims that non-beryllium alloys are superior in this regard. Thus, brushing with toothpaste under these extended in vitro conditions appears to increase the biological liabilities from elemental release for all alloys, but primarily for nickel-based alloys.

Assessment of dental material degradation product toxicity using a bioluminescent bacterial assay.

OBJECTIVES: This study examined dental material degradation product toxicity using the Microtox bacterial bioluminescence assay as well as the effects on toxicity of selective leaching, chelation with protein, the physical form of the products, and synergistic/antagonistic interactions among released ions. METHODS: Polarization was used to produce ionically dissolved (ID) and precipitated corrosion products from Litecast B alloy specimens, which were then chemically analyzed to determine their composition and to identify metal valence states. Corrosion product toxicity, as well as that of the individual alloying elements, alone and in the presence of mucin, was analyzed using Microtox. A mathematical approach identified synergistic/antagonistic interactions and determined element contribution to product toxicity. The mechanism by which the Microtox test bacterium interacts with solid products was explored. The toxicity of methyl methacrylate (MMA) monomer was also examined. RESULTS: Precipitated corrosion products were found to be more toxic than ID products. The metals in the precipitate have been shown to be available to the test bacterium. Be and Ni were the most toxic elements in the products and contributed significantly to their toxicity. Synergistic and slightly antagonistic interactions were observed in the ID and precipitated products, respectively. Mucin decreased toxicity of all elements except Be. MMA monomer toxicity was found to be low compared to metal toxicity. SIGNIFICANCE: Microtox is useful for evaluating dental degradation product biocompatibility and has significant promise for use in other types of studies, such as determining the effectiveness of antimicrobial treatments.

Effect of burnout temperatures on strength of phosphate-bonded investments--Part II: Effect of metal temperature.

OBJECTIVES: It had previously been found that the strength of phosphate-bonded investments is temperature sensitive. However, while the effect of heat from the cast metal is expected to have some effect on continued reactions and melting, there is no published report dealing with this. It was the purpose of this study to consider further the effects of burnout temperature on strength and the contribution of metal casting temperature and investment composition. METHODS: The disc-rupture test (Luk, H. W.-K. and Darvell, B. W., Strength of phosphate-bonded investments at high temperature. Dental Materials 1991, 7, 99-102) was employed to determine the effect of burnout temperature (ranging from 400 to 1000 degrees C) on the 'actual' strength of six phosphate-bonded investments; the cast metal temperature was controlled to be the same as that of the mould. Atomic absorption was employed to investigate aspects of the composition of the investments. RESULTS: The 'actual' strength obtained in this test was always higher than the 'service' strength observed in similar testing with the metal at a fixed temperature (1460 degrees C). The 'actual' strength was also temperature sensitive, but with a different pattern of variation compared with the 'service' values. All investments tested were found to behave plastically at high temperatures. Calcium, sodium, zinc and iron were found in appreciable quantities in the investments. CONCLUSION: Heat from the high-temperature casting metal has a material effect in decreasing the strength of phosphate-bonded investments. Such heating increases the plastic behaviour of the investment and this, together with the casting pressure, may result in a distorted mould and thus inaccurate castings, a hitherto unrecognized source of error. 'Actual' strength gives no guide to the 'service' strength, emphasizing the need for tests under service conditions. Composition affects investment high-temperature strength substantially.

An electron microprobe investigation of the extent of microsegregation occurring in base metal dental casting alloys.

Standard tensile specimens were cast from a cobalt base commercial partial denture casting alloy, and from a nickel base alloy. Specimens from the castings were examined metallographically. The electron microprobe was used in order to determine the degree of microsegregation present.

Porosity of dental gypsum-bonded investments in setting and heating process.

The porosity of gypsum-bonded investments for set and heated compacts was measured and theoretically computed quantitatively, because porosity is an effective factor for determining the strength, setting/heating expansion, and permeability of compacts at casting. A helium gas pycnometer was used to measure the solid volume of fine powders, powder-water mixtures, and porous compacts. The compositions of the conventional cristobalite investment and rapid-heating type investment were estimated from the measured solid densities of the as-received powders and the set investments. The porosity and water content of the set investments were determined from the experimental data. Excess water content in the set investment was calculated in relation to the elapsed time from the start of mixing with water. The experimental porosities of the set and heated investments were about 40% for dry set >compacts and about 50% for fired compacts, which well agreed with the numerically computed estimations, respectively.

An aid for verifying the nature of dental casting alloys.

A geologic field test was modified for determining the presence of gold in dental alloys. This qualitative test gave positive evidence for the presence of gold in most of the alloy samples tested containing 59% or more gold. It is recommended that dentists use this procedure for color comparison of castings to alloy ingot samples of known composition. More definitive professional assaying may be desired for confirmation.