"That's why guns like the AK and FNC are so great; I've seen AK handguards catch on fire and FNC handguards get soft but the gun is still firing, no gas tube to stop the fun."
The AR gas tube is not a very good fuse in my opinion. I have seen 900rds through an M16A2 in about 10minutes, and the barrel got red hot, handguards started to melt, FH came off and went down range, and the gas tube was still intact.
That's why there are really two categories:
1: damageing the accuracy of the barrel
2: ruining the barrel
Damageing the accuracy is pretty easy (like I said 400-500rds fired fast can do it.)
After you screw up the accuracy, it levels off at about 4-5MOA and then you can abuse it as much as you want with almost no deterioration, unless of course you fire enough to make the barrel droop, at which point it is totally destroyed for all intents and purposes, something I have never seen done.
To me, 4-5MOA is about as "ruined" as a barrel can get. that's pretty piss-poor perforemance.
I wouldn't worry about catastrophic failure or barrel droop without a suppressor attached, because basically you have to try really hard to get them to occur.