Firstly, please do not think I'm bashing nV here...that's not my intent.
2ndly, when your foundry company has NEVER released a chip with zero leakage, to expect them to be able to is foolish at best, and outright stupid at worst.
Explain GRAW 1&2 then. Explain 3DMark Vantage. No Q/A to be done. Ageia had already done all of that, and I personally know when and how it transpired, as I bought a Phys-X card very shortly after release. Worked fine until the new libraries were released, and the very FIRST nV Phys-X driver broke it. Sure, it took some time before this happened, but we got nV guys saying "First, we make sure that what we release doesn't break anything", and this couldn't be further from the truth when talking about the titles released before nV took over. Now, NOTHING works. And them breaking that function by disabling it required no cash, but they could have also wirtten code just as short to see if it was an Ageia card, and popping up a disclaimer that functionality could not be guaranteed, rather than allowing the driver for the Ageia card to be installed, look like it's working, and then have it do NOTHING.
This cost nV money(the "support")...they actually paid the NGO guys off to stop development/threatened lawsuits upon release. Here's your cost-less solution for ATI cards, and nV squashed it like a bug. So much for offering it for free...it cost money to ensure that AMD did NOT get it free.
If you go back to then(first nV driver for Phys-X, August 2008), and check my posts on XS, you'll find both myself and others complaining about the issue. I just find it comical that it took this long for the media to pick it up...nV breaking Phys-X w/ ATI cards isn't something new...far from it. They have just recently completely disabled it with ATI and nV cards together, but they broke the Ageia cards almost 1.5 years ago...they bought Ageia february 2008, and by August, released the driver than broke the add-in Ageia cards, a short 6 months, not 1.5 years. And the only way to fix the function, after installing the nV driver, was a full OS re-install...I spent many months on this issue back then, then finally gave up and sold my Ageia card.
http://forums.techpowerup.com/attachment.php?attachmentid=31890&stc=1&d=1262819541
When it comes to thier own cards, paired with ATI cards, and gpu phys-x, I can hold no fault, but them disabling configs that already had been tested, and were working, is in-excusable.
As to the yields...if Fermi wasn't so complex, we'd have had a release of the lower-bin models by now, but even that hasn't happened, so yes, this issue is VERY underestimated. But shortly after Jen Hsun visted TSMC in person(first half of OCtober), we had TSMC's CEO publically state that they had yield issues, and that they were fixed. We are now almost 3 months later, and given the supply issue ATI is having, clearly the problem as only fixed a couple of weeks ago, if at all.