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Old powder giving off a corrosive gas?

In my vault I notice a couple of guns with bad rust all of a sudden. But, its only on a few of them, and it is very light. The floorplate on a model 70 was orange but wiped clean. On an old model 71 Winchester that was also in a case but on the floor, it was more like rust and I could feel the roughness of the rust before I took it out of the sock. It is very unusual, hit or miss on whether a gun has it or not.
I was storing all my powder in there. Most of it is relatively new, as in less than 10 years. I have one paper can of unique and the steel bottom has the same orange dust on it as the guns. But, the power looks and smells normal. I have one old 8lb jug of surplus imr4895, it was down to about 1/3 pound. It was new to me in 1998, last year when I opened it one day, a reddish fog came out of the jug. Today there was no fog, but the powder was all clumpy. It was sitting on a new wire rack unit, steel rack with bright cad plating, under the jug the rack is dark brown almost rusty looking and emanating away from the dark parts the cad looks oxidized until a few inches from the jug it was normal and bright. The jug does not have any cracks, or holes and the plastic feels normal. Last spring I had that jug sitting in a milk crate with several other newer jugs of powder, a mysterious orange dust like substance was on the other jugs under the surplus jug. It was like someone dumped a spoonful of super fine orange powder.
Needless to say, I dumped the remainder of the powder. But I am now a little concerned about the shells that I have loaded with it. I was shooting some 308 the other day and they were fine. But I looked at some 7mm bench rest and a few of the necks were green with thick corrosion. Could this powder now be unstable?
The powder has never been stored outdoors, never in a hot environment, never left open.

Ideas?
 
It was new to me in 1998, last year when I opened it one day, a reddish fog came out of the jug. Today there was no fog, but the powder was all clumpy. It was sitting on a new wire rack unit, steel rack with bright cad plating, under the jug the rack is dark brown almost rusty looking and emanating away from the dark parts the cad looks oxidized until a few inches from the jug it was normal and bright.
Sorry to hear it, especially these days when this stuff is tricky to replace.

Those were all the warning signs so you definitely lost that stuff, but I can't say why.

One thing I will add, is that storing your powder in a strong closed metal container is the opposite of what you want should there ever be a fire. The concept is to store in a sturdy cabinet, but one that would retard the heat while venting easily should the stuff ignite. Otherwise we might add the tragedy of a bomb instead of just a bad fire.
 
A gun safe with powder inside is a bomb, and could produce tragic results (definitely structural damage, likely injury and possible fatality). Powder stores must have a relief panel so pressure doesn't build. My solution was to get some cheap shop cabinets (thick strand board frame and doors, thin masonite back panels) that have locks if access must be controlled (kids, thieves, nosy employees, etc.). If you have the skills, there are threads on this forum about building dedicated storage boxes that meet national and state fire codes.
 
Its not a gun safe by normal standards. It is a room unto itself.
However, back to the question, could the powder be emitting a corrosive gas THROUGH the closed container? Is the powder potentially unstable?
 
However, back to the question, could the powder be emitting a corrosive gas THROUGH the closed container? Is the powder potentially unstable?
Even though the container is closed, it will not contain gas.

For a long time I just "assumed" that as powder degraded, it would lose energy. I had some IMR 4350 that was going bad (less than 10 years old, always properly stored) that I had recently loaded some ammo with. I shot some of the lower loadings at the range and found the pressure was significantly higher than previous experience had been. Yes, consider it unstable. Remember the recall on IMR4007SSC? It would basically self ignite.
 
Its not a gun safe by normal standards. It is a room unto itself.
However, back to the question, could the powder be emitting a corrosive gas THROUGH the closed container? Is the powder potentially unstable?

Decomposing powder gives off NOx (oxides of nitrogen) which will appear orange/brown) will pass through polyethylene containers. In the presence of water (humidity) NOx will further degrade to acids such as nitric and nitrous acid; those are strong acids that are highly corrosive to metals and will degrade plastics. In case you can't tell, I'm a chemist and have some experience in this area.

Even though your vault is a room, you have to consider how much powder is in the room. Burning powder produces gases with hundreds on times the volume of the powder - a few pounds isn't an issue, but 100 pounds without adequate pressure relief (blowout panel) is still a bomb.
 
For starters, you should send that 71 Winchester my way. I have some virgin 348 brass that needs to go on it's honeymoon if you get my drift
 
I had a container of H4831 start gassing enough to push the press fit lid open a bit, start smoking and I put it outside and knocked the lid off. It eventually caught fire and burned slowly.
 
I have been storing my containers of powder in sealed trashbags to contain any gases that may be leaking out. Not sure if this is harmful for the powder but it seems that it would be beneficial to everything else around the powder that could be harmed by the offgassing.
 

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