Just out of curiosity, mic several bullets and see if you're getting consistently .355 diameter.
Usually, setback is associated as a result of recoil and usually heavy recoil.
No, 3X isn't too many under normal loads. I've got some that I've fired, shoot, maybe 9 times or more. Primers pockets get loose after a while, and I toss them. I do load in lots of 1,000 and keep track of firings.
Federal and all other 9mm brass that I know of is built to SAAMI specs and should not be the problem.
I would not normally worry about .005, however, I think we need to be a bit cautious in case you're getting compressed loads. Bullet profiles vary between manufacturers, but 1.135 is what Sierra recommends for their FMJ. Hornady lists 1.150 for their FMJ. But, just what powder are you using? And, please double check your COAL. Double-check your neck size out of the sizer and again out of the expander. Really should just have to take the bell out. Engraving the bullet as you state would suggest that, under normal circumstances, you're over taper crimping.
Not being familiar with RMA (but others on this forum use them), I went on their site and found the information copied below on their FAQ. I personally have never seen anything quite like it. I would highly recommend you're calling them (208-816-3859) and discussing the issue before going too much further.
What are pulled or demilled components?
SOURCES OF PULLED or DEMILLED COMPONENTS:
Major ammunition manufacturers typically inspect every lot of ammunition they produce. During the inspection process, they may find any number of factors that would make the lot unacceptable. These factors include but are not limited to:
- Wrong Bullet
- Wrong Bullet Caliber
- Wrong Bullet Weight
- Wrong Powder
- Wrong Powder Load
- Wrong Case
- Case Flaws
- Over/Under Pressure
- Too Much/Little Crimp
- Missing Flash Hole
- Backwards Primer
- Damaged Case Mouth
- Any other factor that would result in an unsafe or unsatisfactory load
Pulled/demilled components may also come from ammunition that was taken in a raid by the BATFE, FBI, Coast Guard, local police, or another government entity. They typically deem this ammunition unsafe and mark it for demilling.
WHY PURCHASE PULLED/DEMILLED COMPONENTS?
1. Great Pricing! Pulled/demilled components are an excellent value to the meticulous reloader. Pulled/demilled components cost much less than new components.
2. Obtain Rare Components! Purchasing pulled/demilled components is often the only way to obtain certain types of components, as they are not typically available on the commercial market.
3. Recycling! By purchasing pulled components, you keep them from being destroyed. These were made with the intention of being used for ammunition. By purchasing and reloading them, you help fulfill that purpose.
Pulled/Demilled cases may have sealant and/or residual powder. This powder should be removed to ensure correct pressures. Occasionally a primer is seated backwards and sometimes bullets fall and remain inside the case. Pulled bullets may have been hand sorted. While we do our best to sort our pulled/demilled bullets, sometimes a stray component comes through that may be another grain, another caliber, or in very rare cases, it may be mangled or unshootable.
Pulled/demilled components are not for every reloader. IT IS ALWAYS RECOMMENDED THAT YOU CAREFULLY EXAMINE EACH COMPONENT. Please only buy pulled/demilled components if you are willing to examine them.
WHAT ABOUT SECONDS?
We also sell factory seconds. Seconds are typically new components that are blemished (spots or surface scratches) or they may have cracks or other defects in their plating. We do our best to list why they have been deemed seconds in the product description.