Its aligned properly. I would say loose carrier key..... but trying 3 separate carriers..... not the issue
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JW, the last couple of BCM barrels I've used had a flat milled dimple instead of the concave dimple. The flat dimple is a little bit larger than the head of the set screw and leaves a little bit of room to play. I'm just wondering if it is possibly covering the port slightly.
This is a coincidentally useful thread for me. I am having the exact same problem with an SBR with 11.5 BCM BFH. That rifle had over 5000 rounds of mostly PMC Bronze without a hiccup. Now, a few weeks after changing the handguard, it's unusable with the symptoms you describe. I've been through all the steps suggested here, just waiting for some time to replace the gas tube. It's gotta be the gas system...either the tube or VLTOR gas block.
If you look inside the gas block and check the gas port hole you will notice it is several times larger than the port itself. Unless it is grossly misaligned it shouldn't be an issue.
I believe that several 14.5 middy users have stated they needed to run some hotter ammo through the gun initially before using the crappy stuff. I have very little Wolf experience so its hard to know if that is true. Is it possible that you ammo is jacked? Bad lot maybe?
Most likely the GB is out of alignment or is not getting a good seal on the barrel. Next candidate would be gas key the is loose or gas rings that needs replaced.
C4