Is there any difference between the American Eagle ammo and the Champion brand FMJ ammo.

As you know both are Federal ammo products and I don't know why American Eagle costs less since both use the same components. I have shot both and both seem accurate so I can't tell you the differences... (other than price)

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In 4 different guns I have compared them in... the 115gr American Eagle is consistently 50-80 fps faster than the Champion brand.

From pulling them apart, AE uses a traditional lead core with exposed base while Champion is TMJ plated. They both use 4.3 grain of the same looking powder and their OAL is slightly different but may be due to the different length of the bullet.

the Champion 45 ACP's I seen had small primers

There's only very slight differences between the two products.

Federal's AE line is their economy plinking/target brand ammo (just like Winchester's USA and Remington's REM-UMC line).

Federal's Champion brand started as an exclusive product for Walmart (notice the Champion's product number starts with WM).