Thanks for the video,
Things are much more clear now.
Going back into my old pre-retirement mode of Engineering and product development, I'm seeing 2 possible explanations though I 'm sure there are more.
One, that bar may have missed the process, where the rails are heat treated or the heat treat process was not done properly. Heat range, process duration, quenching and drawing all are possible culprits.
The second, is the bar was fabricated with an incorrect steel alloy. If the carbon content in the alloy is not to spec, proper heat treat is impossible. I do not know where Oregon gets their steel. I do know from experience if it's from certain countries, China being one of the biggest offenders, the material certs accompanying the order are not worth the paper they are printed on. It was SOP for us to have an independent lab test samples of the parts or raw material from the developing countries for verification prior to use in manufacture. Without going into detail, all to often we found "liberties" had been taken. Not just steel, but castings and polymer parts as well. ASTM, ISO, SAE, ANSI, MIL and other material specs are universal and not secret.
The fact Oregon showed such concern and wanted the bar back for analysis may indicate this is not an isolated incident but may be an issue with a manufacturing lot, or several lots, of production. In fairness to Oregon, this last statement is conjecture on my part, but having been through a couple product recalls in my time, assessing and understanding failure modes and is key to getting a feel for the potential as to how big a problem may be.
In my own experience, I have found Power Match bars to be not the best, but certainly more than adequate quality for their intended use.
Please keep us updated if you hear anything further.
Take Care