.....and every time, it's been Hornady brass.
There you go, it has to be something Hornady is doing/not doing or using...
The quality of the alloy, the drawing process, or possibly just the specs on the brass itself being insufficient to survive more than a single firing, and some not even that?
We're so used to the usual way things work we overlook the fact that, unless they voluntarily take on the obligation, stating so, neither gun nor ammo makers are required to produce ammo that does more than feed, fire and eject properly.
I don't know who's running Hornady these days, possibly some bean counter with no more personal stake in the company and its reputation than his paycheck (and if so, tis a sad thing),, Seems to me that if the bosses at Hornaday had the same kind of dedication that Joyce had they'd be looking into and fixing this issue ASAP.
Do you know the story about the early problems with the .458 Win Mag?
Sales were poor, and lots of stories about the .458 "underperforming" were being heard.
Hornady went on safari. Didn't tell people he was the guy making the bullets Winchester put in the .458. He listened to the PH's and their gripes, saw some of the failed bullets (I assume that's the story anyway) came home and redesigned the bullets. After that, bullet failures about went away, and the .458 became the go to "budget" elephant rifle in Africa.
Point here is that the big guy took a personal interest in the problem, and it was solved in short order.
That ought to be happening today with the .460 brass
is it??