Yep, repair/board replacement no good. Board replacements are coming from the older batches. My full macbook replacement fixed it with the March 2020 build date.
I think I found something though, on stackexchange forums. I'd made a note of it in one of my earlier comments without realising it was the cause of all this (maybe).
I always plug my charging cable & dongle in the left side, because I am right handed so don't want my mouse to bump in to the cable or dongle. I noticed on my original system and subsequent board replacements, the machine would get very hot when cable was plugged in on the left, as opposed to the right. Turns out the psu is on the right hand side. Plugging in to the left side on one of the faulty systems results in a kernel task being created to route power over to the right side of the board. For some reason on the faulty boards, the kernel task took 3-4 minutes to complete. This results in queueing kernel tasks, eventually your CPU is overcome with this endless kernel loop and panics the next time you give it a heavy task. Kernel tasks survive a reboot, which explains why once your macbook starts freezing a lot, the only way to stop that is to wipe it. On the faulty systems, plugging your charging cable in to the right side resulted in kernel tasks that only take up to 15 seconds so they complete before a queue is possible.
On my replacement system, the macbook doesn't get hotter if plugging in on the left side, and doesn't create kernel tasks that last 3-4 minutes. No idea why that is.
This could be why a lot haven't experienced the issue, some people like to plug things in on the right side and thus avoid the kernel task queue on a faulty system. Some people don't have a faulty system and the kernel task queue doesn't happen at all. It does mean there are users out there though with a faulty board who will eventually plug their charge cable on the left side and trigger the endless kernel task queue to route power, and be where a lot of people in this forum are at now.
Basically, if you do have a system that keeps restarting, completely wipe it, and only use the right hand side ports to charge. Of course this isn't a fix, but at least it'll make work on a machine built for work usable till you can get a replacement, and when it comes time to demo the fault to apple support, start charging with the left ports. 👍
Although the issue exists on other mac systems, it seems certain MBP 2019 16" units are affected by this severly, other batches not so much.
https://apple.stackexchange.com/questions/363337/how-to-find-cause-of-high-kernel-task-cpu-usage?answertab=active#tab-top