Very detailed report. Will read all of it when time permits. After a quick scan, one thing that caught my eye was table 5 listing the difference in calculated inner/outer race surface contact stress levels between the FAG and SNR designs. Would expect to see lower design contact stress levels on the inner race than on the outer race, since the loaded sector of the fixed (with respect to load) inner race surface sees more load cycles.
It was also interesting to read the problem began with surface spalling on the outer race. Surface spalling of hertzian contacts usually originates from a subsurface shear failure. This type of subsurface shear failure tends to propagate at a 45deg angle out to the nearest surface from continued rolling contact cycles. Normally, the location of max subsurface shear stress in a hertzian contact, like this planet gear outer bearing race surface, should be well within the carburized case depth.