I have had the exact same problem with an 8 gig PNY micro sd card in my Samsung alias, i tried formatting it on the phone and it says the format failed
If the phone failed to format the SD card, try to format it through your computer. Connect the phone through the USB port located at the back of the tower. You'll be prompted that the PC detected 2 USB drives, the phone and the SD card. You will see it by going to My Computer folder. From there, right click the Letter drive represents the SD drive then select Format. I hope this helps.
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