There is nothing wrong with "90nm".
Stop blaming "90nm" GPUs for the 360's problems. There's nothing wrong with them. The 360's ability to deal with the heat they generate was/is a problem, but not the fact they were "90nm".
Shut up about "90nm". Waiting for "65nm" just because it is not "90nm" is stupid.
There are plenty of superb, ultra reliable pieces of hardware that use TSMC's 90nm process. My PC's GPU uses TSMC's 90nm process and it kicks out a great deal more heat than the XGPU. AMD's fastest and most power efficient parts are still made on "90nm" processes, and Nvidia still use it for their high end graphics chips. Just stop this "WAAAAAAH MS are stupid/lazy/cheap for not already using 65nm GPU".
Changing over to TSMC's 90nm eDram process (which Falcon does) is probably a good thing, and I wouldn't be suprised if the GPU as a whole now consumed less power, and generated less heat, as a result. The seemingly revised main GPU chip may possibly require less power too (as yields have almost certainly improved drastically).
Also worth noting:
- Lots of reliable things use x-clamps
- A percentage of all hardware fails
- The RROD is a general hardware failure warning and future Xbox 360's will still see this and it doesn't mean OMG STUPID MS HAVE DONE NOTHING TO FIX TEH 360 PROBLEMS 90NANNYMEETER!!!!!
Reducing power consumption and heat generation - as has happened in the Falcons - is a GOOD THING and makes the GPU cooler's job easier, makes keeping everything else cool easier and probably means the 360's flaky, heavily loaded PSU (they didn't leave much headroom) should cause far fewer problems.
If MS wanted, they could easily make an all 65nm 360 that screwed up more than Zephyr/Falcon, so if you want a 360 just buy one and play it.