Casting Porosity Can Reduce the Load Margin at Stress-Concentrating Geometry

What the evidence preview establishes

Failures initiated at predictable high-stress features while extensive gas porosity reduced the effective load-bearing area. Possible alloy variation and loading at the trailing end were additional contributors, linking both casting quality and application stress to the failures.

Why this case matters

Fracture origin, local geometry, internal porosity, and applied load direction should be evaluated together. A part can fail at the expected stress concentration yet still have inadequate margin because of distributed casting defects.