First, let me respond to Dozier Mark...
I didn't say the bullets WERE the problem, I said it was likely they were. I've used plated bullets from different sources in 9mm, .357, .45ACP and .45 Colt. Some were very good, some less so. My experience is that the quality and consistency of plated bullets can vary a lot, between different makers, and even between batches, so I put them first on my list of things to check when an issue arises, IF it does.
Brass: Yes, some can be "too thin" although I personally have never had that issue. I've been loading .45ACP since the early 1970s. My mixed brass stash includes several boxes worth of brass from those days. I've reloaded them, literally, dozens of times, and while a case does crack from time to time (maybe half a dozen in the last 40 years, I don't anneal them) that is the only issue it has ever given me, with GI brass or brass from the major US makers (including RP).
I even have a few cases headstamped RA 18, and other than being a dark brown that tumbling doesn't make shiny, no issues with them, either.
Dies: I use mostly Lyman or RCBS. I have a couple LEE die sets, and as I said earlier, I don't like them. A personal matter, I don't care for the way they do some features. They do work, I'm just not fond of them. ANYONE can have a "bad" die, meaning just enough out of the tolerance range you need, although again, I've never had it happen to me, personally.
It is quite possible that the OP's problem is the result of "stacked tolerances", and changing just one thing can stack the tolerances in a different way, and the problem goes away (or sometimes just
changes...
The relationship between thickness of the brass, actual diameter of the sizer, actual diameter of the bullets used, and the expander matters. Crimp matters. A bad crimp can turn a good round into a bad one.
Except if I may, 'hard cast' is better in high pressure/velocity calibers such as 357, while 45acp likes a softer lead alloy.
I agree and disagree, depending on where you draw the line between hard and soft. I use the rule of thumb. Meaning, whether or not my thumbnail can leave a deep gouge, a small dent, or just a bright spot on the bullet.
My experience is that the .45ACP semi autos don't do well with dead soft (pure lead) bullets, and often don't like the slightly harder swaged slugs. "Medium" hard (small dent) works ok, and hard (bright spot) works well. Revolvers, of course, don't care.
I currently feed a couple of 1911A1 pattern guns, a Sig, two revolvers and a semi Tommygun with my reloads, with "hard" cast bullets, with no issues.
for the .45ACP hard cast bullets benefits are in feeding, (hard lead "slides", soft lead can "stick") more than velocity performance. In magnum calibers, hardcast shines, as one can use more of it's benefits.
The problem of neck tension in .45ACP is long known. Not a problem when everything is done right (stacked tolerances), but can be one when something is just a little bit off. Take a look at GI ammo, and old commercial stuff, and note how a LOT of it has a case cannelure, or even an actual crimp, to keep the bullet from going deeper in the case, no matter what.
Most current commercial ammo no longer does this, dropping the extra work (and cost) from making the best ammo practical to making the best ammo generally acceptable. I do understand that. I don't like it, but I do understand it.
Some people think that bullet setback (poor neck tension) is something inescapable, but it isn't, if rounds are made the right way, instead of just good enough to work (once).
One fellow I know got 2 boxes of Federal 185gr JHP when he got his .45, in 1980. He shot it all but one mag full, which he kept as his home defense ammo. FOR OVER 20 YEARS!!!!
Those rounds had been cycled through the action so many times the nickel plated cases had brass stripes. The bullets NEVER MOVED. (yes, it was checked and measured, often). Those rounds did get fired in the early 2000s, and guess what? flawless performance, shot to perfect point of aim, just like they did in 1980. That ammo was built RIGHT!!! It CAN be done, but these days, I think it seldom is....