Over the last 15 years I’ve had a several card failures. One fell apart in my hand; I was able to reassemble it long enough to get the images off. I got a “card full” error while shooting the total solar eclipse (the card wasn’t full). I had another problem which I can’t recall the details of.
I had such a Sandisc card about 6 years ago. It was a fake. The memory chip inside was much smaller (and slower) than specified when I checked with a test software. It did let you take as many pics as you wanted, never showing a "card full" error. It was cleverly programmed to simply overwrite older pictures when full.
The fakers did that to extend for as long as possible the time it takes the buyer to realize he has been duped. A few days is all the seller of fakes needs to sell a sizeable number of fakes, cash his money, disappear from our earth, and set-up a new seller account to flush and repeat.
A more detailed explanation from the net:
Fake storage devices are often low capacity storage but their on-chip interface is configured to report a larger size. SD cards and pendrives normally have raw storage space that is a power of 2 in size. A small percentage of the raw space is used internally, and also to provide a small number spare sectors to be used if a block of storage is marginal in manufacture or becomes suspect after heavy us of the storage.
If a smaller chip is disguised, then normally it means that one or more address bits will be ignored. For example, a 16 GiB chip might pretend to be a 64 GiB chip.
16 GiB = 17,179,869,184 bytes
Two extra address bits can mean a reported size of
64 GiB = 68,719,476,736 bytes
Without the extra address lines actually existing, the same 16 GiB of space is being addressed as four separate spaces. Once more than 16 GiB of data is written, further writes will start overwriting earlier writes. This not only means that earlier files may be overwritten or corrupted, but also means that the actual structures of file systems may be damaged, which means files may be lost or fragmented.
If you stay entirely within the real raw space, then you can have a workable 16 GiB drive. This will normally require a partition to be defined that limits the usable space not to go beyond the real raw capacity.
Unless you’re shooting video or 30 fps sports, it’s hard to fill a 64GB card with images in a single session.
In any event, the only sane response is to trash the card. Taking a chance on it failing again, and this time when it’s a non-repeatable event, is too great for me.