Your problem has a lot to do with the Federal brass being noted for being soft "BUT" that's not the whole story. Federal .223 cases have a thinner flash hole web that allows the primer pocket to expand more than other cases. These type Federal cases are a real bad problem with reloaders who shoot AR15 rifles. The primer pockets loosen up and can score the bolt face and the primer can fall out and jam the trigger group.
To test for these type cases with a thin flash hole web I use a 2 inch steel rod that has a counter bored end to fit over the flash hole. The counter bore fits over any burs at the flash hole and keeps you from getting false length readings. And any cases with a thin flash hole web are scrapped.
Below 95% of the brass below in my scrap brass bucket are factory loaded once fired Federal .223 cases with over sized primer pockets and thin flash hole webs.
I use pin gauges to check for loose primer pockets, I have two pin gauges .0005 smaller in diameter than the primers being used. If the pin fits into the primer pocket that brass goes into the scrap brass bucket. Brass is a expandable item and your bolt face is not, I load for my sons AR15 rifle and "Dad" isn't going to be blamed for a etched and damaged bolt face.
Any seated primer that feels loose when being seated is tested with a Lee depriming tool. And any primer that moves with just finger pressure the case is scrapped.
And last but not least when you are shooting warm loads in a .223/5.56 you should use primer with a cup thickness of .025 for their added strength.
Also how much you bump the case shoulder back controls case stretching and how far the primer can back out of the primer pocket when fired. Shoulder bump or how far you push the case shoulder back when full length resizing is equal to your head clearance. And head clearance is the air space between the bolt face and the rear of the case and how far the primer can back out of the primer pocket.
Below you can see the outside edges of the primer flattening out and becoming less rounded as the pressure builds when fired. This backing out puts extra strain on the primer edges and can cause them to rupture. Bottom line, the thinner primers are for lower pressure cartridges like the .22 Hornet and the thicker .025 cups are for high pressure cartridges.
Below is a exaggerated example of base expansion from high chamber pressure meaning beyond the elastic limits of the brass. You can also see how a thicker flash hole web adds strength to the base of the case.
Now use a black felt tip marker and blacken the base of your hard to chamber cases. If you see rub marks the base of the case expanded beyond limits and your cases are junk.
The above message was brought to you by the "Society for the Prevention of
Cruelty to Bolt Faces".
