AR-15 Rep said:
Looks like the problem is all around the BC to Buffer contact. When you assemble the rifle does the BC touch the buffer? it should be touching the buffer pushing it back slightly. If there is a gap then the BC slams against the buffer, it could be just a little bit and then you have a hammering effect between the two.
Okay, so I checked closely tonight while cleaning the Bushmaster from some shooting.
Both the Colt and Bushmaster buffer assemblies appear to be composed of non-ferrous metals (neither will react to a magnet). This satisfies one possibility that someone raised in this thread.
I also checked the situation that AR-15 Rep mentioned... The bolt carriers on both rifles push ever so slightly into the buffer spring when the rifles are assembled. So, they do both have similar contact.
I also looked at the retention detent, and it appears far too short to have made the marks on my Bushmaster's buffer assembly... This mark also appears to match up nearly exactly with the back face of the bolt carrier (so I will assume that the bolt carrier caused the damage to this surface).
In examining the bolt carrier, there are no burrs on the metal, and nothing appears abnormal about this part (smooth and consistent).
So, I'm still sort of at a loss regarding the cause of my rifle's situation! Fortunately the etching appears to be fairly superficial at this point... It isn't deep enough to feel a difference in thickness between the marred surface and the rest of the buffer. Nevertheless, the area where the abrasion occurred does feel rough to the touch.
My guess at this point is that perhaps Bushmaster either:
1) coated their bolt carrier with a more abrasive finish than is used on the Colt rifles
or
2) Used a buffer made out of a softer and less durable metal (though I'm guessing both are some type of aluminum alloy).