I've seen that Lucky Gunner article before, good info.
Steel case is cost-effective, so if your gun shoots it, go ahead and use it. They mention the barrels on the steel were shot out- after 10k rds in 2 days. Started keyholing around 5-6k. My takeaway from that:
- Last I checked, I can get cheap steel-cased ammo around $350 per 1k, this is the Maxxtech Essential Steel stuff made by Vympel. It was actually less, including shipping. The mentioned brass-cased ammo, Federal, is around $600 a case, and then you figure shipping extra. If you're going with a cheap, entry-level shooter AR, you can buy a replacement barrel with the savings on one case, and still come out ahead. You could buy a complete rifle after 2 cases.
- I would have to assume one of the factors for the increased wear is shooting while the gun is smoking hot. A couple mags down the pipe will not affect the steel as much as a continuous flow (we're talking 5k a day, for 2 consecutive days). They mentioned the guns got so hot that a couple of the Eotech optics had heat-related issues, they also said at times they would fire off 10 mags (300 rds) in a row rapidly. It was mentioned that they had both dust-storms and rain, and kept shooting through these events.
- I mentioned the Federal specifically, because that's the only brass-cased ammo they tested. That's relevant because it seems the issue with the Tula (vs Brown Bear or Wolf) was the powder. It follows that any untested brass might have a different powder charge than Federal's (Winchester, IMI, Wolf Gold, PPU etc).
- One thing mentioned in the Lucky Gunner review was the build-up of carbon in the gas key and gas tube with the steel; I clean those when I clean my rifles. I shoot a little brake cleaner through them, and run a pipe cleaner through it.
Looking around the internet for specific problems with steel cased ammo (not just "I've seen failures"), I've come across a couple things.
- The stuck case: I've seen this mentioned, seems attributed to the steel case's lack of elasticity compared to brass, allowing some gas bleeding around the case instead of sealing it off. Chamber gets fouled worse, and if you don't clean it well it could build up and give you problems.
- Stuck case with revolver: I have seen this mentioned on the S&W forum. Seems the case expands differently than brass, causing 38 or 357 etc cases to stick in the cylinders.
- Extractor issues- I've seen this brought up a lot, that steel is tougher than brass on extractors; but that always seems to be anecdotal fears, not documented events. I've seen someone do Rockwell hardness tests on steel, brass and nickel-plated cases, the hardest by far was the nickel (which was the expensive self-defense ammo). I've had to replace 3 extractors total on my firearms- 2 were on (older) Pre-B CZ 75's, that were fed exclusively brass 9mm by me. If you explore the CZ forum, you will see that extractors on those guns are a bit of an issue; I replaced both with extractors from the CZ Custom shop that were specifically stated to address that issue. I also had one extractor on an AR pattern rifle fail- very early. It was a Bear Creek Arsenal 7.62x39 upper, they use a different, thinner extractor (I believe designed for one of the 6.5 calibers), and the tooth sheared off. I replaced that with an $8 standard 5.56 extractor, which has functioned 100% with this caliber. BCA sent me a free replacement, which I have kept as a spare. Of note, I have since picked up a second BCA upper in that caliber, and everything thus far has been fine. So for AR's, I just keep a couple extra extractors around. I often take the extractor out when cleaning the BCG, it takes about an extra minute total to remove and reinstall.
Interestingly enough, I have one rifle that actually prefers steel over brass. This is a Century C308, which uses a lot of Cetme parts. The gun is roller-delayed, not gas driven; the chamber is fluted. The C308 is the cheaper cousin to the PTR and HK guns, but they all employ the same design (and thus would have the same potential issue with steel vs brass). The fluted chamber allows for 'floating' the case, to make extraction easier. This causes the distinctive striations on the case afterwards. In the 7.62 NATO vs .308 Winchester question (similar to the 5.56 NATO vs .223 Remington), it seems the NATO cases are the slightest bit thicker than the commercial cases. Not sure if this is why, but occasionally I get a brass case stuck in the chamber- the brass has expanded out into the flutes, and is stuck tight. I never get this with a steel case. The gun isn't a sniper tool, I get maybe 2 MOA with it. So it's not just cheaper to run steel, it's more reliable in this one.
I've had zero issues running the cheapest steel .45acp through any of my inexpensive (Armscor, ATI, Tisas etc) GI-type 1911's. Being primarily a 9mm shooter, I've always tried to keep the 45 as close in price as possible. This has meant grabbing Blazer Brass and S&B when it was cheap, Freedom Munitions reloads... but I've done Tula, and even Hot Shot steel and it runs just fine. We're talking $300 1911's with Sarco mags, zero malfunctions, center-mass hits at 25 yds. That's all I ask of those guns, serves my purposes just fine.