I think the early bolt breakages were due to certain manufacturers making 58-60ksi ammo for a system (AR15) that can only really handle 50-55ksi consistently.
Something like F=P*A... Increase the A on the bolt face and keep the pressure the same and load on the lugs increases.
It was mostly M&A Parts imitation bolts made from 8620, incorrectly heat-treated, didn't even take the time to figure out what an actual Grendel bolt is.
Last Bill A. was at AA before going to HK, he said their High Pressure Test rig (for destructive testing, not non-destructive testing) was still going strong after many years dating back to the start. I think he used a process similar to the Canadians on how to make AR15 bolts, as opposed to the way the US military TDP calls for them to be made (HPT non-destructive on all of them, then MPI).
He radiused the lug roots to compensate for the deeper bolt face (which is there because of extractor lip thickness and Grendel rims), added that depth to the tail of the bolt so standard firing pins won't protrude excessively from the FP aperture, and did a bunch of other little things to design a long-lasting bolt.
The material for the bolts is a very specific 9310, and heat treating has to be controlled well like any other AR15 bolt. As long as the vendor has good processes and competent engineering, with a thorough TQM process, the bolts are fine.
I'm on at least 7 personal Grendels now, with who knows how many I've helped with their own builds, and have only broken 5.56 bolts to-date.
I have bolts from:
AA regular and hard use
PF/Maxim nitrided
Group Buy Monster bolts
LaRue
JP also makes a great bolt. I have friends that own several of them and love them.
The Grendel case in the AR15 works at lower chamber pressure, while increasing propellant volume and using the 30˚ shoulder for efficient and consistent burning of the propellant. Since the case is so short, you get a lot of room to work with in the AR15 magazine that just isn't there with most other cases.
I'll have a 6mm AR soon after the group buy goes through with PF. We're doing Criterion pipes with the White Oak Armament competition extension and thread pattern for the tenon.
I would love to see an LMT Enhanced 6.5 Grendel bolt made from AerMet for that project, with the .136" depth/2.810" bolt OAL.