A long time ago in the early days of Linux Kernel Porting in Philips Semiconductors
We were using SD cards for booting our early ports of Linux kernels onto Philips ARM9 SOCs .
The SD cards used to die with monotonous regularity.
Eventually we worked out a theory as to what was going on, partially guided by reading patents from the big name SD card manufacturers.
When an SD card is formatted in the factory it is FAT16 or FAT32 formatted.
It turned out from the patents that at least some of the flash controllers would do flash write levelling by directly using the DOS FAT File Allocation Table data to decide what was used and unused data on the card.
If we formatted the card with a Linux file system, in our theory, the FAT region (left untouched in the Linux partition and format ) still reported a basically empty card to the wear levelling - so almost any sector was fair game for a rewrite.
Our ext2 file systems would get trashed by something as we kept on writing yet another root file system or system start up logs.
What we did to solve the problem was to keep the FAT formatted partitions.
Then allocate a large data file using the FAT file system.
Then loopback mount the data file as an ext2 formatted file system. (whatever we had as state of the art in the 2000's )
Activity in the loopback mounted file system would then appear as random writes to the FAT file system, wear levelling would "realise" we meant to use the allocated blocks in question. So it never went and trashed our file systems.
We just arranged our Linux machines to boot from FAT ..
We were much happier with our SD cards after that, they lasted a lot longer.
I wonder if this is still going on - direct mounting SD cards as Linux file systems causing problems with the SD cards embedded controller assuming FAT formatting and wear levelling by stealing your data. .
As an aside, at another employment we found that the Samsung EVO 3D Multi Level Cell (MLC) technology SD cards were head and and shoulders ahead in write cycle lifetime, ahead of even some special "robust" industrial Single Level Cell (SLC) tech flash cards.
We were investigating loop writing video and audio into a storage device as a black box and we wanted years of lifetime. The Samsung cards would have delivered.