Things Haven't changed? I think that a lot of things have changed in metallurgy, engineering, machining and especially in litigation in the last 160 years when it come to barrel steel. The commercial muzzleloading guns are a modern high carbon chromoly barrel steel probably 4140, that's why they can safely build a 15/16" .54 barrel. GM barrels are 1137 steel (Chromoly), That's why they can safely build 15/16" .54 barrel. In my last post, I stated that when I spoke to Rice about making a drop-in for my T/C hawken with his 15/16" .54 barrel, He didn't recommend it due to the dovetails and screw holes. That makes me wonder what barrel steel he is using. I believe it is probably 12L14. It's a carbon chromoly steel but it is alloyed with lead for easy machining. I believe that most if not all of the known barrel makers like Getz, Rice and Colerain to name a few make their barrels for kits and the traditional builders who use traditional tools i.e. files for their metal work so they're probably using 12L14. Sleepy Hill made their barrels from 4140 but they don't make them anymore. We in the U.S do not have a safety standard when it comes to muzzleloader barrels, european manufactures are legally required to proof their barrels and by coincidence most if not all of the commercial muzzleloader barrels seem to come from Spain or Italy. Would 12L14 barrels survive their proof standards? I sure don't know. Douglas no longer makes muzzleloader barrels do to litigation. I don't know what black powder pressures reach with 1,2 and 3F pushing a PRB, conical or shot load but I do know what the different barrel steels can handle (see below). Maybe wee need to stick to the .200 minimum wall thickness. I load my 12L14 barrels as thought they were made in the 1700's. I'd love to hear any BP load pressure data.
12L14
Tensile strength 78,300 PSI, Yield strength 60,200 PSI
1137
Tensile strength 108,000 PSI, Yield strength 76,100 PSI
1144
Tensile strength 108,000 PSI, Yield strength 89,900 PSI
4140
Tensile strength 148,000 PSI, Yield strength 95,000 PSI