RC no disrespect but I do not agree at all with your statement
If the hammer simply followed the bolt carrier down, it would not have enough energy left to fire the primer.
I know that this can and will happen. if the disconnect is not correct. It may be a hammer spring tougher than it needs to be or it may be that the disconnect is slightly holding the hammer till trigger release but it's something close to this that happened to me.
Regardless we can probably both agree this is an EXTREMELY DANGEROUS condition.
I understand about an AR15/M16 not firing out of battery, but I also read where the AR15 bolt is designed to "catch" the hammer if it is riding the carrier forward.
The disconnect is designed to do that.
http://www.youtube.com/watch?v=NtwhZj1_TlI
At about the 8:45ish mark you can see this process it is an M16 but the concept is the same. Towards the end of this video is the M-16 parts and the functions in automatic.
Here is the cycle of what happens starting with the bolt in battery and the trigger holding the hammer at the trigger sear.
You pull the trigger releasing the lower hammer sear.
The hammer swings forward contacting the firing pin (the firing pin is free floating design in an AR. It has no spring holding the pin off the primer)
Firing pin strikes the primer launching the bullet pressurizing the gas port
the pressure in the gas tube pushes the blot backwards.
The hammer rides the back of the bolt backwards and is caught by the disconnect on the hammers disconnect sear.
The bolt comes forward loading another cartridge.
You release the trigger and the disconnect sear is released and the hammer swings slightly forward and catches on the trigger sear again. (On my rifle I can now hear a click as it catches again on the trigger sear. When the disconnect was not correct it was very very faint if it did catch at all)
The last step is what was wrong on my rifle as the timing between the disconnect sear and the trigger sear was off and I could literally hold the trigger half way and cycle the hammer back and forth by hand with the upper off of course and the hammer would not catch on anything.
The disconnect was a cheap stamped unit and was sloppy and loose and neither the disconnect sear nor the trigger sear would catch the hammer every time.