AbstractIn Part 1 of this paper the microstructures generated in the Pb–Cu system at copper contents less than the eutectic content of 0·06 wt-% were studied for sheet produced both by the conventional method of rolling from heavy cast block and by a direct casting method without rolling. In Part 2 the mechanical properties associated with these microstructures are investigated and the mechanisms by which failure occurred are considered. Similar levels of tensile strength and thermal fatigue resistance are obtained but with lower tensile strain to fracture in the cast material. Both materials are considered satisfactory for use in flashing and roofing applications.MST/1465