"Why are cast-on spears always so fragile?" Topic

In an earlier post, I mentioned my fondness for Front Rank 1st ed Jacobites. I like the more realistic proportions.
What I did NOT like was the propensity of the Lochaber Axe to snap off at the hand of the charging Jock.

In fact, I have found this to be an almost universal weakness. Cast on spears are almost always weaker than the option of gluing a spear to an open hand.

Is there smoething about forcing the molten metal through this hole that makes it weaker?

For some reasons, swords in the same position are NOT weaker, but spears are.

While there are several production events that might happen occasionally to cause that, I suspect the tendency for the longer spears to get all bendy in packaging and/or shipping means that by the time the end user gets them there is already some metal fatigue somewhere along the spear.

Is there smoething about forcing the molten metal through this hole that makes it weaker?

Could be. Crystalization of the alloys in use can be accelerated by certain flow characteristics. There are also possible issues with bridging if the viscosity is a bit too high for the pathway.

It's even worse on smaller figures… and I have suffered a bit from this recently, especially because the little things are very difficult to straighten.

Better question yet, why have cast on spears?

Never seen that. Nevertheless I always replace with wire anyway (so prefer cast on so I can drill out the hand myself) … ah well …

Weak points in the metal are formed anywhere you have a SUDDEN transition in size (like from the hand to spear shaft or where the ferrule of the spear head flares out to form the head). Rods (like spear shafts)are weaker in this case then something like a sword blade (whice is sort of rectangular)or irregular shapes which have a bigger crossection to distribute the stress over. It's worse on smaller figures because they have even less area to take the strain.

I don't know nothing about casting. But I'd like to learn.
Could part of the problem be using pewter instead of old fashioned casting alloy? The old stuff seems like it was easier to straiten without breaking.
Sorry about spelling errors.

The thin casting part cools/crystallizes faster then a bigger part. So you don't have crystals forming across the change of size making for a very week point in the casting.

Yes the new led free medals are a lot harder so break easier

I do wish someone would produce a cheap plastic line of 28mm weapons line for various eras (and a separate one for 25mm). I have the way rifles, spears, axe handles, pikes ad infinitum, bend. It really kills the look of many models.