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55 grain FMJ Quoted:
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Lot number is on the last picture in the opening post.https://www.AR15.Com/media/mediaFiles/126115/20180909_215113-666962.JPG I'm thinking out loud but I'm wondering if they accidentally kept the same powder charge for 50 or 55gr projectiles when they switched to heavier projectiles, or alternately, didn't completely clear out the powder dispensers from a switch from fast burning powder to slow burning powder. I would've expected better from the Lake City plant. |
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Another picture of a spent case up close. https://www.AR15.Com/media/mediaFiles/126115/20180909_221036-666954.JPG |
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Here are a few empty cases we found after the Kaboom.https://www.AR15.Com/media/mediaFiles/126115/20180909_215804-666944.JPG Heavy ejector smear in ARs. Few missing primers. Made my mini14 look like a Glock ejecting vertical. 
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Your friend needs to be really sure that he saves those cases and the rest of that box of ammo, too. Get in touch with Hornady with this evidence and I think you'll find that they're very interested in dealing with your friend in a fair manner.
He has them by the balls, pretty much. If Hornady asks for you to send them the unfired ammo, send them SOME of it for testing but retain some for evidentiary purposes and be sure to tell them that this is the case. Document everything. Don't let them bury evidence. I don't think Hornady would do that but it never hurts to CYA. If they're not REALLY helpful and willing to cover replacement costs, then speak to an attorney. The evidence is clear enough. This is a solid product liability case in the making if your friend chooses to escalate to that level. That lot of ammo needs a recall at the very least. This is why I only shoot my own handloads. Because I know EXACTLY what goes into each and every one of them. |
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What was the temperature when your friend was shooting? Was his ammo laying in the sun before he shot it?
Some powders burn faster at high ambient temperatures. Same problem if he let a cartridge sit in a hot chamber for a few minutes before firing. This could cause overpressure. If he shot it on a cold winter day, he probably would not have overpressure. |
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What was the temperature when your friend was shooting? Was his ammo laying in the sun before he shot it? Some powders burn faster at high ambient temperatures. Same problem if he let a cartridge sit in a hot case for a few minutes before firing. This could cause overpressure. If he shot it on a cold winter day, he probably would not have overpressure. 
But what do I know, I shoot in the sun all the dang time with a bunch of loaded black pmags cooking before they get fired. |
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What was the temperature when your friend was shooting? Was his ammo laying in the sun before he shot it? Some powders burn faster at high ambient temperatures. Same problem if he let a cartridge sit in a hot case for a few minutes before firing. This could cause overpressure. If he shot it on a cold winter day, he probably would not have overpressure. |
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Had a friend that was having a ton of issues with his new Springfield Saint AR-15 and Frontier (but LC branded?) ammo. We're still not sure if it was the rifle, the ammo, or both. Basically had a lot of FTE/FTF issues, blown primers.. primer debris would get stuck in the trigger assembly area and impede trigger function. Charging handle would get stuck and we'd have to use a multi-tool to force the bolt back and eject a chewed up fresh round. Happened every range trip after 2-3 magazines. In fact, the Frontier was noticeably more accurate than the Winchester, Federal, AE, PPU and Fiocchi I was shooting along side it. It has been better than 2.0 MOA in a couple of my guns. I’m curious if it’s overcharged or a defect in the weapon. |
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I've put about 150 rounds of various Frontier ammo through my AR's, a Marlin X7 and a Savage 12. The only problem I've had was hard primers. About 10 rounds required a second (or third) strike to set off the round. But never observed any issues with primer set back, blow-out, piercings, etc. In fact, the Frontier was noticeably more accurate than the Winchester, Federal, AE, PPU and Fiocchi I was shooting along side it. It has been better than 2.0 MOA in a couple of my guns. I'm curious if it's overcharged or a defect in the weapon. Quoted:
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Had a friend that was having a ton of issues with his new Springfield Saint AR-15 and Frontier (but LC branded?) ammo. We're still not sure if it was the rifle, the ammo, or both. Basically had a lot of FTE/FTF issues, blown primers.. primer debris would get stuck in the trigger assembly area and impede trigger function. Charging handle would get stuck and we'd have to use a multi-tool to force the bolt back and eject a chewed up fresh round. Happened every range trip after 2-3 magazines. In fact, the Frontier was noticeably more accurate than the Winchester, Federal, AE, PPU and Fiocchi I was shooting along side it. It has been better than 2.0 MOA in a couple of my guns. I'm curious if it's overcharged or a defect in the weapon.
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Its interesting also because I've chronoed this load and its noticeably slower than IMI, PPU and LC M193.
I've had zero issues with the 62gr SP, 55gr FMJ and 75gr T2 5.56 loadings. In fact, they're all fairly slow for 5.56 loads. My 75gr handloads are faster than their T2 and I'm not even close to max loads (24gr Ramshot TAC). I've got several hundred of the 75gr for a rainy day. I'll have to shoot 5 from each box over a chrono to verify pressure 
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Wow. Serious over pressure signs. Quoted:
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Another picture of a spent case up close. https://www.AR15.Com/media/mediaFiles/126115/20180909_221036-666954.JPG Call Hornady tomorrow, they need to recall that production lot, if every round is loaded like that. |
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Here are a few empty cases we found after the Kaboom.https://www.AR15.Com/media/mediaFiles/126115/20180909_215804-666944.JPG
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Why even the chance? If we went off anecdotal evidence nobody should ever shoot IMI 77gr, 55gr, LC XM193, Independence 193, etc...lots of mainstream loads have had overpressure issues at some point. Looks like all my 75gr T2 is one lot. Ill shoot one box if its good I'm not going to lose sleep over it. I've shot some already but may as well check again. |
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Is this ammo actually loaded by Hornady or loaded by LC for Hornady? The mystery will be who is at fault. Is it Hornady for demanding a spec that's too hot or is it LC for a lack of quality control? In all of this, I'm just surprised Vista Outdoors (aka ATK aka Federal/Speer/CCI) has agreed to a joint venture with a competing company (Hornady). Last I knew, ATK has the contract to operate the LC plant. |
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Is this ammo actually loaded by Hornady or loaded by LC for Hornady? |
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Quoted: Press articles make it seem that it's loaded by LC using Hornady projectiles, and then sold by Hornady under the Frontier brand. It should've been quality economy ammo with that combination but it's now obvious that there's issues. The mystery will be who is at fault. Is it Hornady for demanding a spec that's too hot or is it LC for a lack of quality control? In all of this, I'm just surprised Vista Outdoors (aka ATK aka Federal/Speer/CCI) has agreed to a joint venture with a competing company (Hornady). Last I knew, ATK has the contract to operate the LC plant. |