Hi Guys
I've been in contact with Coy at CCI. He's been very responsive and informative with respect to the concern about the aluminum case ammo. My reason for sticking with this one is simple: I've got a s**tload of it, as a result of the unavailability of .40 S&W in my area.
According to Coy, CCI has been making aluminum case ammo since 1980 and has made literally millions of rounds, so this is not a new process for them nor is their engineering or design untested. He said that he was not personally aware of the specific incident we talked about on this forum but I made him aware of it and he was going to look into it.
I asked if the internal cartridge pressure of the .40 S&W was of any particular significance and he indicated that the max pressure (SAAMI) is 35,000 psi for both the 9mm and the .40S&W so the .40 doesn't present any special or unusual problems.
I'm not trying to convince myself that these aren't going to be a problem, checking the spent cases and cleaning the gun completely after each range session is a something that I plan on doing as I always do.

You check the spent cases on every round you fire??

Yep. I pick 'em up, take a quick look and drop 'em in the bucket. Always check the firing pin dent and anything else that's obvious.
I used to reload and I guess it's just a habit now.

Non issue around here, none of the ranges allow aluminum cased ammo.

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Minimize the variables

I have shot a ton of blazer brass in my 9c & f/s 9 without ANY problems. Not much alum. case though.

I have shot a ton of Blazer aluminum 9mm and .38 spec. and a good bit of their .357. No one I know has had a problem with it, none of the ranges around here have a problem with it, but one place I've been to up in PA won't allow it because they claim head separation problems. I personally like it, but if I can get brass for a little more, I do.

.40 caliber ammo is available by the boat load up here in NW PA. 5 or 6 months ago when ammo was really hard to get it was often the only pistol ammo you could get at Walmart.
Anyways, a few years ago I went to visit a friend in Ohio that owns a 1928 Thompson sub machine gun. We fired a whole case of Blazer aluminum through the gun without a single problem.

Ok, now you are just bragging!

Ive shot in in my .40 shield with no issues. Still have a couple boxes of it around. So far Ive not found any ammo my shield wont gobble up and spit out with no problem.