I did some more research today at work into the laser HAZ issue, and while it is an interesting point, feel that it is probably not the most likely root cause for short pick life.
Talking to our in-house laser guru, he felt that my estimate for HAZ depth was somewhat overstated for steels, but probably pretty good for titanium (which I somewhat ironically have more direct experience with laser trimming.) He suggested that <.005-.015 is probably more realistic for 0.150 thick low alloy steel, which is very much laser type dependant. A YAG will be on the low end while a CO2 laser will be on the high end of this range.
I also thought a bit about the reported failures and in general wouldn't characterize them as high cycle fatigue, where laser HAZ cracking becomes an issue. It seems like the material is just brittle and that's why it breaks. This could be caused by a number of factors including the raw material type and quality, heat treatment, pick shape, loading, or combination of these factors.
My metallurgist friend at work is on vacation for the next few days. I'll discuss this issue with him when he's back and pass on any thoughts that he has on the subject.