I've shot lots of the American Reloading pulled 50gr frangible "brown tips". Specifically, in government speak, they are the pulled bullets from SEMI-JACKETED FRANGIBLE MK 311 MOD 0 5.56 cartridges. I call them brown tips to differentiate from other 5.56 frangible bullets, as that is what they look like to me, but I realize they really don't have a separate tip, just tarnished copper showing. I got mine when they were cheaper and more available. Glad I got them when I did.
My observations and experience with them:
They need a fast twist. 1/9 accuracy sucks. Some 1/8 shoot them fine and some 1/8 shoot poorly. I use 1/7. Maybe they'd shoot good in slower twist if the velocity was increased, but I have no need to try that.
If the AR likes them, they are capable of 1 1/2" at 100yd. My Ruger Precision 5.56 will do 1 1/8" at 100yd with them.
I too have problems with a uniform oal when reloading. I shoot for a 2.25" oal, measure each loaded round, gather up all the ones over 2.26" oal and simply seat them a little deeper.
I started out low with IMR4895 and WW748, working up until the rifles functioned and I got the best accuracy. It ended up for me that 23.5gr IMR4895 and 23.5gr WW748 met my goals. Since I have plenty of 4895, that is what I use, but worked up WW748 as a backup load. Some of my rifles prefer CCI 41, some prefer Wolf KVB223M, and some like both these primers that I use in AR's. In my opinion, I am not using a hot load. For example: my XCR-L 7.5" pistol gas system is normally set on "1" for ball ammo; it needs to be set on "4" to function with the frangible bullets in 70 degree weather and "6" when it's cold (for Florida).
For a steel target test, I put a 3/8" AR500 steel plate inside a brown single layer corrugated cardboard box used for shipping. I shot the steel plate through the box at 12yd, wearing face, double eye, and head protection, firing multiple shots. Opened the box and looked. None of the bullet fragments penetrated through the sides of the box. A few pieces did stick into the box sides, but could not be felt from outside the box. Mainly it's the jacket material. The core mainly turns to "dust" with a few larger chunks on the ground. My steel targets are normally shot at 35yd. I have no fears of shooting at steel at that distance with these bullets. Have also shot plain steel at 35yd. Out of a 16" bbl on plain steel, the bullet MIGHT be creating a tiny dimple, or it might be just a buildup of the copper core where the bullet hit. Out of shorter barrels there is just a smear where the bullet hit.
Here's a couple of velocity averages I'm getting all with 23.5gr IMR4895:
16" Tavor: 2739.5fps at 10' from chronograph
10.3" Daniel Defense Mk18: 2344.9fps at 10' from chronograph
I keep throat wear records on all my .223/5.56 barrels. These long frangible bullets don't wear the throat any more than other jacketed bullets.
I like them...people noticing them at the range can think that are armor piercing from the darker tip. One also has to caution shooters not to shoot at steel that close with regular ammo, lest there be target damage or bounce back of bullet parts.