Possible that they work hardened by many loadings? If I remember my metallurgy correctly, Work hardening in brass occurs only when the metal is plastically deformed; strained beyond its capability to return to original size and shape. A cartridge in a properly fitted chamber should be able to withstand a very large number of firings without resizing or annealing.
From this batch of 20 I had 1 hull split on the last firing. Where did it split?
It maybe possible that these hulls are finally just used up? If the hull fits the chamber there is no such thing as "used up."
Paper hulls are the best for black powder but there is just something about all brass hulls and old hammer guns. Why do you think paper is best for BP? I'd think brass much superior, other than that hulls must be cleaned.
DDA