[sgtnoodle]

I've personally seen many dozens of SD cards fail such that they don't even know their own sector count anymore. My suspicion is that in-progress wear leveling operations aren't rebust to sudden power loss (ejecting card without unmounting it). Most likely firmware specific...

[petrosagg]

Yes, and this problem is exacerbated by the raspberrypi's microUSB power input. We've seen countless number of cases where a Pi exhibiting SD card corruption was also experiencing undervoltage. If you're using raspberrypis in production it's paramount to have a good microUSB cable and power supply