"Hard cast" around here,...has basically become a term to describe almost anything that is harder than pure lead.. In other words, about all the folks that advertise their bullets will use the term hard cast lead. It is really a worthless (ok, maybe that's a little strong) term and gets you asking more questions than it answers. Get a book and do some reading about "bumping up" etc. and the way lead bullets work as you fire your round.
If your barrel has a very smooth bore, etc., it has been said more than once that leading is more often caused by bullets that are too hard rather than too soft...And also that as long as they are soft enough, and your barrel is smooth enough inside,..you will never get leading (see if you can find someone with a freedom arms gun that has a leading problem).
If your barrel has rough spots in the bore,..you are bound to get some leading there until you deal with the rough spots,...it's really a gun fault more than a lead fault.
I switched to lead a few years ago. I had read that John Linebaugh said their pressure spikes and irregularities dissappeared and things became more predictable after they switched to lead for their testing of their guns.
I have a chronograph, and I can attest that after I switched to lead, velocities were much more predictable and usually had quite a bit less deviation between shots (of the same powder,bullet,and primer). Seems like you get a higher velocity with less powder also.
I don't believe I will ever shoot anything but lead in my straight jacketed cartridges anymore. 30-30 I will still use leverevolutions,..although I've got a lead bullet mold for it also, should I decide to change. I also have some leverevolutions for my 45-70. But I got into those before I got my 45-70 mold.
There are some formulas out there (don't have a url handy, though) for lead hardness,..given a certain pressure level (it is reallly the acceleration that determines optimum hardness). If you accelerate too fast, the too soft bullet will plug up the bore nicely, but will also deform a little and you won't be very accurate. If you accelerate to little (for a given load) then your bullet will not bump up and plug the bore at all, and you will get flame cutting around and up the sides of your bullet. So, there is a sweet spot,..that is what you are theoretically trying to find.
One more word about hardness. Things like monotype lead are so hard I believe you can do 30-06 with them. But they are also hard enough that they can shatter on impact. A better solution is to use something that is initially less hard, but when you are casting, drop (quench) them in water,...then the outer areas had a hard rating, but the inside is less prone to letting the bullet shatter on impact...(theoretically, of couse).
Anyway, this is just me thinking out loud. Let me pre apologise for all the bad spellings, but I hope this helps out.
remember, as a rule, lead is nowhere near as hard on a gun as jacketed.
Oh, I just remembered a place where you can get a wealth of information. And they have a lot of articles online and stuff. I think their name is the Los Angeles Silouette Club, or something like that. Of course, now that governer moonbeam is going to outlaw lead...not sure where that will put them.