Camera is a Ixus130 / SD1400 IS
On a Sandisk 32GB SD card
Don't see anything obvious with the port, it's a 2010 camera, so it does need multiparition for a 32 GB card, and the CHDK code to support it is there. Shouldn't be any reason to use exFAT on a card that size.
It is multi-parition, though I'm just wondering as to why that error has been happening only now. Before STICK used to format the card correctly, it's strange.
Yes, that's a bit odd. I guess an OS behavior change making stick misbehave might be possible? Are you using windows?
If you want to investigate further, you could try reformatting the card completely (in camera, or delete all the partitions and format the whole card from a PC) and starting from scratch with stick to see if behavior is reproducible. If it is, the first thing to check would be whether both partitions are accessible from a PC and which files are present on each.
Or you could just say it's working now and leave it at that
Is the card the same one that was corrupted previously? If the card is actually failing, that could cause all kinds of issues which might appear to temporarily resolve by formatting. I recently had one in a raspberry pi where reading some files would return different data each time, although by chance no of the files required to boot the OS were affected so it mostly seemed fine.