The attached photo's show the results of a high pressure incident with a S&W 59 auto pistol. I am a firearms instructor with a large agency. Besides front line weapons, we keep quite a collection of other armorment. We are required to test fire all weapons once a year. I was spending a couple days doing so, when I opened a case of S&W 59, 9mm pistols. Take a gun out, fire a clip, return to case, repeat with the next gun, and so on. Well, our Special Operations Team at the time trained with "Simunition" barrels on the 59's. These guns were stocked with red plastic stocks to identify them, plus the Simunition barrel can not chamber a real round, with the barrel diameter about 32 cal.
The case of weapons I was test firing were regular duty weapons. Imagine my suprise when I fired one and it felt like a firecracker going off in my hand. The magazine flew from the gun, the slide was jammed open, and the frame was cracked in the grip area, as well as on one of the slide rails. Someone had installed a Simunition barrel on a duty weapon, and it chambered and fired a live round.
Now, I have no idea what kind of pressure we are talking here, driving a 124 grn. .9mm bullet at 1250fps down a .32 cal barrel, but it must have been quite impressive. If you look at the attached pics, you can see the fired casing blew out in the webb, dumping a lot of pressire on the next round in the magazine, tearing the jacket from the bullet. If you look at the fired case, you will see the bullet jacket welded to the inside of the case. The pressure must have been so great that it pushed the lead core of the bullet out the barrel, while the jacket was driven back into the casing where it fused with the case. Now, a lot of people say they can spot high pressure by looking at the primer, so look at the one from the fired case in question. Looks pretty normal.....
Accidents are usually a combination of things that combine to cause an incident. Pat attention to what you are doing, and don't depend on a safety, or gun designe that is subject to failure. After this incident, the Simunition system was withdrawn from service when it was found several other barrels were also able to chamber live rounds.
Larry