Either everyone mentioned in this thread with failures isn't reporting them to Estes, or Estes is lying. The customer service agent just told me they have only heard of two E12 failures worldwide so far.
Evidently they aren't submitting MESS forms either.
If there is indeed a problem, posting it on a forum is not a substitute for informing the manufacturer or the certifying organization.
The bottom line is that
not everyone reports the motor failure to both the manufacturer and fills out the NAR mess report. Without reporting to both, neither the manufacturer nor the certifying authorities know about the failures. Period.
Let's look at a typical year. S&T typically receives between 100 to 150 MESS reports a year. That's not a lot of reports, so all hobby rocket motors would appear to be very reliable. Correct? Maybe, but we can only go by the statistics.
We know from a number of public sources that Estes makes several million motors a year. If we assume that 50% of the MESS reports involve Estes motors, than the reported failure rate is ~75/3,000,000 or only 1 failure in 40,000 motors! That a 99.9975% overall success rate. Really good, and much better than APCP motors.
We also know that a Mabel, the Estes motor production machine, produces about 600 motors per hour, and that Estes tests 3% of their motor for quality control, so they probably make about 5,000 motors per shift day per Mabel and probaby have 4,800 available (1600 3-packs) for sale after testing and obvious rejects.
From what I have complied from this TRF thread, and other sources, 13 catos of E12 motors have been reported somewhere,
and not all have been reported to Estes and NAR S&T. 12 of these motors were from lot A 8 18 11 and only with -4 and -6 delays. We can look at the raw failure rate which is about 12/4800 or 1 in 400. That's a 99.75% success rate. A good bit lower than the overall reported rate, but still very good. In fact there is a stastical 70% probability (0.9975^144 = 0.7) that when Estes tested ~144 motors as part of their daily QC, not one motor will fail! A 1 in 200 failure rate is required to satistically have a better than 50-50 chance to have 1 motor cato in ~144 motors tested.
The analysis above assumes a totally random system, which may or may nor be valid. If the black powder or the clay is not totally homogeneous, then you might have an abnormality in a few consecutive motors. If you change the process, for example, the delay time, the first few motos may be slightly different. These are manufacturing processing uncertainties that could be missed in random lot testing. However from the reports I read, it looks like most of the catos were random, and only 1 or the 3 motors in a pack catoed. If it happened to you, it is unfortunate, but the probability of it happening is statistically low.
While one E12 lot may warrant further scrutiny, but unless there is an ageing problem,
and verified with continuing documented reports of problems with that lot, even that lot failure rate is not high. Later lots don't have reported problems, so at present, I wouldn't loose sleep over using Estes E12 motors.
Bob