Case tore right in half about midway up from the base. What the heck causes this??
Usually, case separation is caused by either too many reloadings on a particular piece of brass or by over-sizing (over working) your brass. Reloading for gas guns requires care to size sufficiently for the tightest chamber to avoid slamfires and commercial reloaders, I would suspect, may size a bit more than most shooters reloading for one particular rifle in order to give them some measure of safety margin. The shooter who reloads for one rifle can use a cartridge case gauge to measure a once fired case from his rifle, then set his dies to form the case just a few thousandths under that measurement, thereby working the brass a minimum amount to avoid case separation.
I am not all that familiar w/223 reloading, but with GI brass in 30-06 or 7.62 Nato, it is common to find brass that has been fired in machineguns with rather sloppy chambers, resulting in more stretching of the brass in this area (the head/web area). Don't know if the full auto 223's have somewhat sloppy chambers as was common w/the larger MG's, but would suspect that would be the case.
Your description of "about midway up from the base" seems a bit unusual to me, however, as work hardened or over-worked brass usually separates right at the web of the case, that is to say, where the case wall joins the head of the case.
Many service rifle shooters feel the need to use small base dies to bring the cases down considerably in size. This causes work hardening of the brass and expedites case failure. Perhaps this is necessary in some rifles; personally, I have never had a problem sizing brass to fit any of my (30-06 or 308) rifles using standard dies.
Just before case failure occurs, it is common for a bright ring to appear at the web of the case. I suspect that is the ring you are seeing on some of your fired cases. You can bend a paper clip 90* and use the hook to "feel" the inside wall of the case for a groove at the web which serves as a warning that the case is about to fail and should be discarded.
Black Hills has a very good reputation in the competitve shooting circles and I would suspect that they attempt to use only once fired brass, but don't know where they obtain their brass or if there is a possibility that it could have been used in full auto weapons or not.
Were the cases military headstamp?
Regards,
hps