I believe the term is called "detonation"... way too little slow burning powder. The primer flash can arch over the powder charge igniting it at both ends causing an out of control burn.. Instead of burning, the powder explodes.
Why you NEVER go below min load unless you have a very good idea of what you are doing and with powders designed specific to low density charges. The load data in my Hrn manual lists H4831... he used H4831SC which has even lower load density. This is where less created WAY MORE.
That action survived a massive amount of pressure. Be thankful the shooter still has all the important bits and pieces attached. I still do not understand why the gunsmith would return that action. Personally, I would chop it up or make it inoperable.
It did its job admirably... you may not get a second mulligan.
Jerry
I don't have my records handy, but I used to do ballistic testing under controlled conditions and probably fired north of 1200 rounds with low powder charges to simulate low velocity (long range) impacts on test coupons. In order to simulate various ranges from a fixed 15m firing point, we did everything from 20% of commercial load data minimums incrementally up to 140%+ for V50 tests. Hundreds and hundreds at the 40% or less range. We had a breach loading single shot universal receiver with proof testing barrels with 4" thick material at the chamber. Over pressure was not usually a safety concern but we did blow out a lot of primer pockets, but that was only on the extreme high end of loads, never on the low end. We did this with various cartridges from .223, several .30 cals, .50bmg, 14.5x114mmR and 20mm.
With the low volume charges, never once had a sign of over pressure. Every shot was chronographed and never once did a low pressure charge result in an unexpectedly high MV. Had lots of inconsistent performance because some times the powder was at the bottom of the case and others at the top, but never over pressure. To solve the inconsistency we used cotton balls to wad the powder down inside the case to ensure that the powder always had consistent orientation and distribution inside the case.
If your "detonation" theory is valid, I can't imagine how we wouldn't have had dozens of these 'detonations' if not more, especially because prior to using the cotton balls, we did some limited testing to explore how powder orientation affected MV and shot to shot consistency. We played around with how we chambered the cartridge to try and figure out what the ideal way to load a partially full case was.
The experiment we conducted was with a 30-06 and 155 gr HPBT MK and about 35 gr of H4831SC. We deliberately used a low charge to exaggerate the effect of powder movement in a less than full case.
We tried three different loading techniques, 25 shots each:
Holding the case bullet up and gently tilting and loading the case to chamber the round with as much powder to the bottom/primer side of the case as possible.
Holding the case bullet down and loading the case so the powder was as far away from the primer as possible.
Holding the case sideways and shaking it to evenly distribute the powder along the length of the case.
What we found was that the closer and more compact the powder was in relation to the primer, the faster the MV. Each method revealed an ES and SD that was more consistent than random chambering (sometimes up, sometimes down) of unwadded cases. Consistent wadding of the case resulted in an even greater reduction in ES and SD.
We duplicated the testing with .50 bmg, 700 gr AP rds and 8 grams of H50BMG powder. Uncontrolled loading resulted in poor ES and SD. Wadding improved both dramatically.
Neither loading technique in either calibre resulted in a single firing with evidence of overpressure. Most of the primers weren't even properly flattened against the face of the bolt.
If your theory is correct, I can't understand how this guy went 2 for 3 with blown primer pockets and we never had one.
If I could propose a modification to your theory, it would be to suggest that instead of the powder beginning to burn at BOTH ends, but perhaps it began burning at the wrong end, and the explosive train of burning powder and shock wave was moving towards the primer pocket, rather than towards the projectile. With the explosive train moving in the wrong direction the primer pocket would be hit much harder than a normal detonation, regardless of overall pressure generated. Then again, if the powder was burning from both ends, the explosive train would meet in the middle, and I would suspect that to cause a case separation instead of a primer blowout and 1 of the 2 bad rounds did separate. But again, with the tests that we did, especially with the .50bmg, I am surprised we did not ever see this with our low powder charge loads.
In closely scrutinizing those photos, I almost want to suggest that they could have been fired out of battery, but I am unfamiliar with that rifle/action. I can't picture how the head space could have been so excessive as to allow the base of the case to expand outwards that much. Maybe in a semi, but not a bolt. Alternatively, a manufacturers defect that resulted in excessively soft brass, or annealing, could explain why the case so readily yielded, but it wouldn't explain why there was space for the brass to yield into. Those case rims are seriously deformed. Has me scratching my head.
I would love to see a picture shown from the side of the cases instead of from the head stamp. I would also love to know the OAL of the 1st fired case compared to the 2nd fired case.
Regardless of what the smith said, I would not fire that gun again until I had a firm understanding of what happened, and I can't believe the smith OK'd the gun.