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Why do some tensile test samples fail before the expected final elongation

Your TA is likely correct. Elongation can be greatly affected by surface finish in some materials. It's not about the loss of cross-sectional area, it's about stress concentrations and nucleation ...
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Why do some tensile test samples fail before the expected final elongation

Elastic strain goes up to about 0.2 % , then plastic strain begins and goes to about 25% for a typical 1020 depending on the nature of the rolling. Your stress /strain curve is not correct.
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Why do some tensile test samples fail before the expected final elongation

Every chunk of engineering material ever put onto an Instron tester and pulled to failure contains manufacturing flaws inside it. The smallest of these do not affect the test result, but the biggest ...
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Why do some tensile test samples fail before the expected final elongation

Likely because the corrosion helped accelerate a microscopic fracture and so the sample failed early.
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