Dry Ball said:
Read recently where shot was harder to come by so some mountain preferred to carry shot and use as needed to cast a ball. Question - today's chilled lead shot is coated with graphite and I understand the chilling actually hardens the lead a little. Can modern shot be used to make round ball? or is what I read balogna?
In case I have not said so - Welcome to the Forum.
Not exactly sure what you read in the historic period? Bar lead was traded in huge quantities, but so were already cast balls in different sizes in enormous quantities, though this was by the French from New Orleans (and supplied all over west of the Alleghenies) and mostly in the Pre AWI period.
Maybe there were some times when shot was as cheap as bar lead, though it would not have been generally true. If shot was as cheap, it would have been easier to cast into larger balls just because of the smaller surface area of the shot would melt easier and faster.
We have had some pretty intense discussions that lead is not hardened or annealed by heat, extensive or fast cooling or even work hardening - the latter like brass will do. The only way to harden lead is to add another material to it like tin, antimony, etc. and it becomes a harder alloy of metal.
Modern chilled shot is usually not pure lead, but usually has something in it to make a harder alloy. Some kinds have more tin and or antimony than others.
Neither Tin nor Antimony can easily be removed from the lead alloy by hobbyists. So making balls from modern shot will most likely work better in a smoothbore as others have mentioned.
Gus