only a bunch of third world countries adopted the 540 series (which was primarily 5.56) and france who very quickly replaced it. And the 542 is currently made and used by one country: chile..... Even the inventors passed it over and went back to the drawing board
The XCR-m was disqualified from the SCAR program because they showed up for a trail day without a BFA... because nobody told them it was required... aka the old boys club forced them out. Also robinson arms isn't a very big company, which was a major factor as well.
You only need a torque wrench for one bolt, and that's if you swap barrels. Robinson arms provides you with instructions for field expedient barrel changes without a torque wrench. Most guns require you to set to torque the barrel, or barrel retainer. You only have to take the barrel off to swap calibers so saying its a deal breaker or unreasonable is silly.
As for the aluminum receivers. AR receivers are al (7075), ACR are AL to. Man modern firearms currently in use are AL.
milspec means nothing, there is so many different types of AL and they all have different properties. Military spec could mean "the minimum requirement for min expectations" which could be a very low bar to meet. Or you could be talking "aircraft" grade part which actually means something for quality, although that too is a fairly broad "standard". As the army(s) uses a lot of different types of AL, with a lot of standards, "mil-spec" is overall, meaningless and a feel good consumer catchphrase.
If you want to compare 6061 vs 7075 that means something. For example 7075 might be stronger, but if you need to weld on it you are probably going to use 6061 for ease, and expediency. However in any given application you have too look at hardness required, if you're casting or milling, forming or welding, conductivity, corrosion resistance, etc... the "strongest" may very well not be the right material for the job.
Robarms has been trying to get a military contract since their "expeditionary rifle" with no success. they don't even have an LEO contract - they are strictly a commercial outfit. We have pages and pages of threads here talking about the XCR and loctite, wandering zeros, the need to run it super-wet, etc. None of it is confidence insipring and I cant imagine they would do well in US ARMY trials at Aberdeen.
Yes, the wrench is only needed for barrel swaps - that would not be a big deal if Robarm wasn't pushing barrel swaps as THE key selling feature (i.e. the "killer app") and putting out literature saying how it's a user-change design feature, can be done in the field, etc.
The SG542 is a licensed copy of the Swiss Arms family of rifles, built using the SA Technical Data Package for the weapon. Sure, few countries buy the Chilean variant, but why would they when they can have the Swiss gun for a small price differential? The SG540 (military version of the 542) and the SG550 are almost identical rifles with only minor evolutionary differences - differences we are thankful for, else the 540 would be a named prohib variant in Canada (much like the XCR likely will be when the next Liberal gun law rolls out).
An interesting fact, the SG540 evolved to the SG541. The SG541 was re-named to the SG550 - the current Swiss service rifle - the only changes being some stamping operations differences to allow for full-auto fire. The SG542 came out AFTER the 541, but is just another semi-auto only version of the SG540 currently license built by FAMAE.
Bottom line - in semi-auto, it's the same design, just made in a different facility. One can argue the Swiss guns are better assembled also.
By the way, I work in the defence industry as an engineer. Milspec most certainly does not mean nothing. I would suggest you google military materiel certification, Non-destructive examination, objective quality evidence, ISO 9000 series standardization, Canadian Forces Technical Orders (CFTOs) and the MIL-STD family of standards that underpin military materiel specifications. If milspec meant nothing, you could cut the DND materiel acquisition budget in half tomorrow

I've done first article testing in the field for CAF gear - believe me, there are lots and lots of "also rans" like the Robarm when it comes to military procurement. And that's a good thing - people's lives hinge on reliability and performance.