These graphics card chips will run
extremely hot with inadequate cooling.

Sounds like the cooling fan and heatsink were not properly attached in the first place.
They can run hot enough to melt the plastic surrounding the chip, or even the AGP socket it is in!.

That smells bad, and can even be carcinogenic.
Another possibility is voltage. But if your 9000 used to work fine, then that shouldn't be an issue.
I'd ask the supplier to take it back and give you another, under warranty. One that the heatsink and fan stays onto!
Good luck, and Welcome to TechIMO!
Cheers
Mick