Ok, lets take this one at a time :
took my new AR-45 to the range yesterday,
Awesome- you lucky devil.
and fired the rounds I'd loaded for my 1911 pistol through it. The rifle barrel is 16 inches long, but I had a lot of unburned Unique flakes on the bench, after firing it.
At subpar pressure- unique burns "uncleanly". This is one of the reasons people complain about it being dirty. You probably just never noticed in your pistol, because you don't shoot it on a bench, and thus can't see the particles.
To ME, unburned powder is lost power (not to mention wasted money)!
While I agree, I also get a lot of unburned unique in well performing shotgun loads- another use for a powder that can be used in so many different applications.
Could I load the 45 ACP rounds, that I shoot from the rifle, with something like IMR4227 to eliminate the problem...or would I be opening up another can of worms?
Can ? Thats a dumpster of worms, and undoubtedly over pressure just thinking about it. If you have burn problems with unique, just wait till you get downlaoded 4227 .... you'll vomit on yourself, for certain.
The M1 Carbine rounds that I load with IMR4227 don't leave any unburned powder...( and I have a BUNCH of it).
Huge pressure difference. Look up the pressures your 30 carbine rounds peak at, VS your 45 ACP's. There is a league of space in there, and you aren't going to fill it. Trying to compare the two is....difficult.
How about using LR primers (Fedaral 400's), since the Unique obviously didn't all ignite in 16 inchs of barrel using CCI LP primers?
While you can bore out LPP's to LRP's, a better idea would be to either :
A. Switch to a cleaner burning powder such as W231, OR;
B. Switch to a Large Magnum Primer, start your load workup back at 5.5 grs of unique, and go from there.
C. Increase to max load of unique, using standard primer, and check for "mess" then.
All three of things could, may, or may not work- but I'd try A and C before B. I've done B, and I use it in full power HP loads, but it was a long process with a chrony, and not something I care to repeat. As it is, I'm certain the rounds I developed are +P, so I cannot provide the recipes to you publicly.
What I actually would like to know is, how did those dirty rounds perform ?
Poorly ? Or did you just not like the "mess" ?