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I think we have several factors working together. One we have a bullet with more bearing surface. Two we have clear indications of excessive pressure. Since the AR gas system works by gas pushing the carrier back and pushing the bolt forward and since the carrier was found to be partially back, I think we can conclude that there was still too high pressure when the gas began the process.
I think you should check the following: Were you using brass that had previously been fired with other loadings in this chamber? When you resized these cases did you check the case length?
The reason I ask is that if these cases had stretched or were too long plus the bullet with a greater bearing surface with even a slightly high powder charge you could have this result. I would take a close look at the bolt lugs to see if they show any damage. Pressure of powders when graphed is not a single line growing at a constant rate. At some point they jump at a much sharper incline. With the three factors above (long case, longer bullet, slightly higher charge) you could have hit the point in the pressure curve where you jump greatly in pressure for a small increase.
I hope that makes sense.
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