OK, my co-worker brought in his little 1" micrometer, & I've checked the thickness of 3 random teeth on the curving chain & on 2 older chains that worked fine but are just dull now.
Curving chain: 0.0557", 0.0559", 0.0560"
Old chain 1: 0.0570", 0.0558", 0.0564"
Old chain 2: 0.0561", 0.0574", 0.0554"
Keep in mind all chains have been used (the curving one a lot less than the older ones), & while I probably should've cleaned them before measuring, I didn't. They appeared fairly clean, though.
So ... since the older chains that worked fine each have some teeth that are thicker than all 3 of the curving chain's measured teeth, I'm going to assume the thickness of the teeth is not the cause of either the curving or the excessive heat.
Next, I laid all 3 chains out here on my desk side-by-side. The space between the teeth on the curving chain is clearly shorter than the space on the 2 older chains; I'm sure those 2 chains have stretched. I laid one of the old chains on top of the newer curving chain, pulled them until they were both taut, & measured the difference between the length of the 2 chains to be 0.1" over half the length of the chain, so about 0.2" over the entire length of the chain. Of course I would adjust the bar to tighten the chain as I'd use those older chains. Is this difference enough to cause my curving & heat?
To me, it's still a mystery. Unfortunately I have no way of taking close-up pics of the teeth.