Hornady brass, correct? If you're expanding the sidewalls out, it's just an itsy bitsy, teeny weenie more understandable. But it still indicates **** for brass, IMO. Should be no problems expanding / fire forming those sidewalls out to the slightly larger diameter.Just so everyone is aware, my case failed from a factory box of 243 ammo in a 243 Ackley chamber after 1 firing in the exact same spot the OP had issues with at 5 firings. Seems too coincidental to ignore to me. Here's 1 case next to the other. Same box of ammo.
I'd send the rest back to Hornady for a refund. Not a replacement with more reject casings. And I'd tell them their brass sucks big-time.