I had tried dd, and got strange results. It would work if I started the command quickly after inserting the card, but if I waited a minute it would immediately error out. However, the command consistently failed at the same point, with the same number of records written to the device.

We've RMA'd the corrupted cards, so I can't continue attempts to recover them, but it didn't look like there was much hope anyway. We're more concerned now about the cause of the failure. Since Samba claims Windows 7 compatibility for the version we're using, I think at this point it's either a freak corner case of software interaction, or a string of bad hardware. The difficulty is that we've chosen to use SLC cards for the very reason that we want reliability for years, and there aren't many vendors selling SLC cards.

I'm really at a loss as how to investigate the cause, short of exercising the file share against Windows 7. Even then, we could probably only diagnose the problem, not resolve it.

2011/8/8 Gerardo Richarte <gera@disarmista.com>
I'm very intereted in the realiability of SD cards, so please share any
new info and improvements!

One thing you could try is to overwrite the sd completely, with
something like

dd if=/dev/zero of=/dev/sdb

be sure it's sdb!

   something else, if you do have a partition table, then you should
try to mount sdb1, sdb2, etc
instead of just sdb. Though I think this is not your case, because the
kernel complains of not being
able to even read the partition table.

you could also try formatting them on windows? using fdisk with -C -H
-S? (though I don't know what numbers to use)


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