Chronograph----The missing ingredient for this strong gun .357 load development. I much prefer to target and chronograph simultaneously. It is more than conservation. There are times when you see a direct correlation between velocity and point of impact. Not always, so it is by no means an immutable rule.
A clear illustration of the correlation between velocity and POI occurs with IMR 4198 stick powder under 300 grain bullet in .45-70, when shooting through a T/C 16" barrel. (I'm being specific with details to keep this anecdote on the rails. Don't recall the powder charge.) Extreme spread measured 150 fps for five shots. Target at 50 yards. Dispersion in an 8" to 12" vertical line. The slowest shot printed highest, the fastest shot printed lowest, etc. Perfect Velocity-to-POI correlation. A slow shot has a longer "barrel time," therefore lifting the muzzle a fraction higher before bullet exit.
Without a chronograph, it would have been conjecture to make that assumption.
As to the strength of the Blackhawk .357 magnum, I have not personally tested it the way we did its steroid offspring, the .357 Maximum, but it is strong. It ranks very high on my list of .357 revolvers directly suitable for deer. It is important to select powder to safely push your 180 bullet as fast and accurately possible. Safely. The .357 is not a .44 or .45 so----besides marksmanship----bullet selection and velocity are more critical.
One can talk metallurgy. Yes, metallurgy and heat treatment are critical to great strength. But so is mass. That is why, for a given cylinder diameter, six chambers is weaker than five. Given equal materials, a .357 built on a .44 frame is much stronger than a .357 built on a .38 frame.
Brass fatigue becomes a factor at upper pressure, therefore hunting reloads should use new, once, or twice fired brass, not stuff that's been reloaded six times.
You state that your .357 case takes firm purchase of the Hornady 180 XTP when crimped in the lower cannelure. Try it that way. Bell the case the minimum amount necessary to start the bullet. Do not chamfer the case mouth. Target your loads at 50 and 100 yards. Not just 25 yds. You need to know the load is consistent, and 25 yds may not tell you that.
David Bradshaw