Jon you are right about hammer forging. I believe Mannlicher leave the rather pronounced spiral on – possibly as a trademark. Watching machine gun barrels beign hammer forged at Enfield, again that took what, less than a minute.
Clive one of the advantages of decent quality black powder is its consistency. Its actually a more consistent propellant than smokeless, and its a lot easier ot set it alight consistently. As a consequence a lot of black powder ammo is very consistent indeed. The problem comes with the business of spin – the generally longer bullets are highly spun for stability, and because of the lower velocities the launch angle or line of departure is realativley steep. Combine htat with being heavily overspun for stability downrange and hte thing locks gyroscopically at a rather awkward angle upward angle relative to the trajectory which is tedious. Tends to fly nose up generating slender body lift as a result of the crossflow, and all sorts. So its not the ancient propellant at all which is darned good – its actually the physics of older lower velocity ammunition whihc tended to limit performance.