Howdy
This was discussed at length on another forum.
Here are a few photos I posted.
This is a very early S&W 38 Hand Ejector that shipped in 1908 as I recall. There were no hammer blocks in this model, hammer blocks came along a number of years later. The OP in this post stated that the parts inside his revolver looked a lot like this.
Notice the shape of the rebound slide and the bottom of the hammer where they meet. Both are rounded.
When the rebound slide moves forward, the hump at the top wedges the bottom of the hammer back, rocking the firing pin back from a round under the hammer.
If the hammer spur receives a heavy blow, the bottom of the hammer may break off at the line shown, allowing the hammer to fire a live round. Also, the rebound slide is hollow. It houses the rebound slide spring. It is possible for the rebound slide to be crushed by a heavy blow, with the result again being a fired round. Lastly, a heavy blow may break the hammer stud (the pin the hammer rotates on) again allowing a discharge if the hammer is struck a heavy blow.
The OP stated that when he took the revolver apart, nothing appeared broken. So I suspect his theory may be correct. The rounded profiles of the rebound slide and bottom of the hammer may have allowed the hammer to force the rebound slide back, allowing the revolver to discharge.
Smith and Wesson was continually tweaking their designs. Sometimes to make things better, sometimes to save money manufacturing the product.
This 38 M&P shipped in 1939. The photo is a little bit out of focus, but we can see how different the profiles are of the interface between the rebound slide and the bottom of the hammer. They have been squared off, there are no more rounded surfaces that might force the rebound slide to move back. Simply speculation on my part, but I suspect this change was because the engineers at S&W realized there could be a problem with the older shape of the parts.
This revolver has the style off hammer block that caused the problem on shipboard in 1944. Yes, a sailor was killed when a S&W revolver struck the deck of a warship and discharged. The hammer block in this revolver is a piece of spring steel riding in a groove in the side plate. It is staked in place. Normally, the spring action of the hammer block keeps the top of the hammer block in position between the hammer and the frame. When the trigger is pulled or the hammer cocked, a ramp on the hand engages a tab on the hammer block and pulls the hammer block back into its groove in the side plate, allowing the hammer to fall all the way and fire a cartridge. A thorough investigation was held into the incident and it was determined that hardened cosmoline in the revolver most likely prevented the spring action of the hammer block from doing its primary function of blocking the hammer. Instead, the hardened cosmoline kept the hammer block in the withdrawn position, so that when the hammer received a heavy blow, something broke and the revolver discharged.
Smith and Wesson had a large contract to supply revolvers to the government at the time. The government demanded rapid resolution of the problem. First, S&W conducted tests of the hammer block, and found that the revolvers sometimes discharged when dropped. The engineers were called in, and the current hammer block design that has been inside S&W revolvers ever since was perfected and put into production in the space of one week.
This Model 10-5 shipped around 1968. It has the same style hammer block in it that every S&W revolver has had since 1944. The hammer block rides in a groove in the side plate. A pin on the rebound slide pulls the hammer block down, withdrawing it from between the hammer and the frame when the rebound slide moves back. This happens every time the trigger is pulled or the hammer is cocked. Again, notice the interface between the top of the rebound slide and the bottom of the hammer. They meet together squarely and there are no rounded surfaces to move the rebound slide back. This style of hammer block is actually a redundant safety device. The hammer block never actually touches the hammer, you can see there is space between the hammer and the hammer block. If something catastrophic should cause something to break, then the hammer block will prevent the hammer from moving forward enough to discharge a live round under the hammer.
I would like to add that Smith and Wesson revolvers discharging when the hammer was struck a heavy blow was relatively a rare occurrence.
Nowhere near as common as accidental discharges with old fashioned Colt style single action revolvers.
These are the parts of the lockwork of a Colt Single Action Army. The upper arrow points to the so called 'safety cock' notch on the hammer. The lower arrow points to the tip of the trigger. Notice how thin the tip is. If the hammer was placed in the 'safety cock' position, the thin tip of the trigger rested in the notch. It did not take much of a blow to the hammer spur to break something and discharge a live round under the hammer. That is why a single action revolver with the Colt design should NEVER be carried with a live round under the hammer. Someday when I have an inexhaustible supply of Colts and old Smiths I may make a study of exactly how much force is required to create a discharge with a live round under the hammer. For now, I suspect the old S&W design was more robust than the old Colt design.