Section thickness changes almost everything about how a casting behaves. Solidification time scales roughly with the square of the section, so a 200mm wall doesn’t take twice as long to freeze as a 100mm wall, it takes closer to four times as long. That slow cooling produces coarser grain, more alloy segregation, and a greater chance of shrinkage porosity in the last region to solidify. Which means a heavy engineering casting isn’t a scaled-up version of a small one. It’s a different problem, requiring different feeding design, different heat treatment, and different expectations about what the material in the middle of a thick section will actually do. This is where buyers get caught out. A separately cast test bar shows tensile and impact numbers from a small, fast-cooling sample. The core of a 250mm section in the same casting, cooled far more slowly, will fall short of those numbers. That gap is normal metallurgy, not a defect, but it has to be accounted for in the design and the specification. A Metal Casting Manufacturer working regularly in heavy sections designs for it. One that mostly pours light castings tends to be surprised by it. Sharma Technocast pours heavy-section castings in grey iron, ductile iron, carbon steel, and alloy steel, with heat treatment, machining, and NDE in-house. For heavy engineering casting requirements, contact Sharma Technocast directly. contact@sharmatechnocast.com +91 9726666123