I forgot this until the recent "Obelisks" batrep, but...
Quote: (Chroma @ 26 May 2009, 13:51 )
It's only when Rallying in the End Phase that a formation without Blast markers can't return units.
Just to illustrate:
Phalanx with 4 remaining units w/ Lord + 3 BMs means they will go to 6 units + 2 BMs (2+1 for leader = 3 = +2 units, -1 BM).
4 units w/ Lord and 0 BMs means no rally.  No increase in formation size.  No choice.
The resulting formations are similar in ability in with respect to shooting and firepower needed to break but 6+2 is more durable if they later phase out (more units rallying off board) and the extra units are better for an assault formation than losing BMs, barring a completely unprepped target.  Even in the case of an unprepped opponent it's possible the extra 2 units could make a difference in outnumbering bonus/penalty that covers the BM penalty.
Plus, if the tactical situation is unusual and BMs are so uber-important that 4+0 is better, the suppressed formation has the option of choosing 4+0 and would do so.  It could even go with 5+1 if that were useful for some reason.
Even taking into account the very small possibility of a failed rally (2+ if within 30cm of the opponent), it is a net benefit for the Necron to have BMs on formations in the end phase.
The "we get tougher and more flexible when we have BMs" Necron rally rule is just wrong.