I think it's a gas escape problem around the chamber.
I've noticed some differences in the o.d. of the 3" and 3.5" shells. The hulls differ in thickness from shell to shell. If the brass does not expand to fill the chamber, there can be some flashback that can cause the burn that you're seeing on the hull.
If the crimp is not filling the chamber, the same thing could happen. There is a lot of pressure and fire when you touch off a shell.
We must always remember it's a "controlled" explosion fairly close to our face.
Thanks,
Clark