dla,
I decided to call afriend of mine that works in a ballistics lab. To your point, he confirmed that the maximum SAAMI pressure for the .45-70 is 28,000 lbs. He said the only reason there is data for 40,000 c.u.p. .45-70 loads in the 1895 Marlin, is because the same action is used with the .444 Marlin whose SAMMI rating is 44,000 cup and with the .450 Marlin whose SAMMI rating is 40,000+ cup. Asked about the possibility that different materials, strengths, are used in the .45-70 vs. the .444 /.450, he said that Marlin has never stated they are different.
He went on to say that awhile back he received a call from Marlin regarding a wrecked .45-70 Marlin that had been returned from a customer. He described it as a case of "catastrophic failure" due to extremely high pressure. The back of the cartridge case had blown out, dumping plenty of gas back into the receiver, blowing off the extractor, a few other action parts, the magazine tube and forearm. Astoundingly, the action held, and the barrel was still in one piece, still attached to the receiver. Upon examination, Marlin determined that the locking lug was still firmly in place but was set back .004".
Asked, what kind of pressure would cause that to happen, he said 70,000+ psi(!). He also said that it was a tribute to the strength of that 1895 .45-70 Marlin.
Have a good weekend!
w30wcf