I'm betting that you are getting gas cutting at the heavier load. Check the outside of the bottom driving band and I bet you see smooth ripples from gas cutting. You may need a magnifying glass but I bet you see some smooth and shiny uneven ripples on that bottom driving band.
I used to shoot a lot of cast boolits through my converted Siamese Mauser back in the 70's and with the hottest loads (top end Ruger #1 and Siamese Mauser rated) I got just a bit of leading near the muzzle with PB boolits. My solution at the time was to add a .410 fiber wad and that stopped it.
I did not have the leading issue with my 1895 Marlin but of course was using Marlin loads for it so a little less poop.
As mentioned,using a boolit of 0.462" may help if there is some gas cutting. Slightly softer boolits may help too but also as mentioned, even with the thick "skirt" he may be getting some flaring now and even if not could well do with softer boolits. A flat base boolit would be a better choice for heavy smokeless loads... in my opinion anyway.
Longbow