I think you're absolutely right about it not being uncommon. Consider that many people buying these haven't figured out how to switch graphics chips, or haven't bothered to, or prefer the 9400M for energy-saving purposes.. Then consider that many people aren't bothering to game or do anything graphically intensive with the 9600M GT enabled.. And of those that are doing those things and are having the blackouts, only a tiny percentage of them would find their way to an online forum and start asking around. Many would just take their computers back, call AppleCare, or maybe even assume it is a software issue and not think much past there.
The fact that we have quite a few people in this forum who have experienced it, plus you can find posts about in other forums on other sites as well, indicates this is quite potentially a widespread problem. I wish we could get more people posting their 9600GT specs from their System Profiler, both before and after "successful" exchanges, and I'd like to know what SMC version they've got running as well.
I have done a PRAM reset, and had the fan comes on correctly for one launch of a game, but after that first launch the fans don't come back on. I got them working again after a full SMC reset while on the phone with AppleCare, and once again after that first launch where it worked, the second launch of the game it failed.
The people over at MacRumors and WoW think this is a BootCamp/Windows and/or World of Warcraft specific issue. I wanted to enlighten them that it is systemic and not program-specific but I can't post because I am not a subscriber.
I think everyone needs to get together as a whole to compare notes or sound the alarms so the mystery can get solved for
everybody. If Apple engineers and we the users can't find the definitive source of this issue then I suspect nobody is totally in the clear, as a software issue could cause it to flare up on the "working" machines as well.