I had the exact same experience years ago shooting skeet with a minty 28 ga. Remington 11-48 skeet gun. Shooting doubles at station 7, the first round just did not sound right and as the gun cycled I saw the brass head go flying out of the ejection port so I lowered the gun, unloaded it and removed the barrel and checked the bore. The plastic case had gone about a third of the way up the barrel and "welded" itself to the bore. Like Paul's OP, we worked for about 20 minutes to finally free the remains of the hull. This was using factory ammo, long ago enough now I don't recall the brand.
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