I wonder if your SD cards lie about the amount of space on them. A lot of very inexpensive cards do that, saying that (for example) they are 8GB but are really only 6GB. If you format a card like misrepresents the amount of space then the format will be "bad", referring to storage that isn't actually there. Writes to missing storage will do something strange, either writing somewhere else or not writing anything.
There are some guides that talk about how to tell if the SD cards are "fake" and how to work around it. A quick google search found
this one and
this one.