Just polling the brain trust... I know y'all aren't psychic. Here's what happened.
I was doing some testing when I started to get unusual behavior from it. Like, I would push a button to change modes and the mode change would happen, then suddenly un-happen. Or a button wouldn't work, then suddenly it would. Then my Arduino started hanging up--just totally not responding at all. No serial IO. No response to button presses. Nothing. After a reset, the Arduino would run for 5-20 seconds, then hang.
The first thing I did was disconnect my Boarduino from my project board. No change.
So I pulled the (suspected bad) chip out of my Boarduino and put the (known-good) chip from my Uno into the Boarduino. I also switched computers from my laptop to my desktop, because my Uno was in a different room. I kept getting sync errors when trying to upload to the Boarduino, so I moved the "good" chip back to the Uno and uploaded the code to it, then moved it back to the Boarduino and the laptop. Surprise, surprise... same thing kept happening. Moved the "good" (not anymore) chip back to the Uno and the desktop... same thing kept happening. Now I have two dead AVRs.
To sum up:
- Bad chip in Boarduino with FTDI cable on laptop.
- Put good chip in Boarduino with FTDI cable on laptop, get sync errors.
- Put bad chip in Uno with USB cable on desktop, freeze/hang occurs.
- Put good chip back in Uno with USB cable on desktop, upload code successfully.
- Put good chip back in Boarduino with FTDI cable on laptop, freeze/hang occurs.
- Connect good (not-anymore?) chip to desktop with USB, freeze/hang continues to occur.
Also, while I was working on the project, before I noticed that the AVR was messed up, I had an LED burn out for no apparent reason. To be fair, I was welding about 3 feet from the board. Welding by itself shouldn't produce enough RF emissions to fry a board, but you never know. Anyway, I'm telling you all that because there were already signs that something screwy might be happening, and it's not like I was sitting at a desk with a nice anti-static mat and all. However, the Arduino was almost certainly NOT directly affected by the welding arc. It was in a plastic (not metal) project box, sitting on top of the welder, not touching the welding table at all.
What I'm wondering is if anybody has any insight into where the failure is. For example, could I have messed up the Boarduino in such a way that inserting an AVR into it fries the AVR? Is that even possible? Or is it my FTDI cable maybe? Or, heck, is it my laptop? All three of those are common to the failed chip(s).
Anyway, maybe the answer is that there is no answer except trial and error. I have some more AVRs on the way, as well as another Boarduino. I hate to play trial-and-error with the AVRs, at $5 a pop, if anybody has any better advice for me.