HOW did you encrypt/password protect the card? Are you using an encrypted file system or some other tool?

If it's not even possible to format the card, as in on the lowest level write to it ignoring whatever is on it, I'd say it's broken and not password protected...

When it comes to passwords, you most likely have a hunch about how many characters you might have used and if you used upper case and special characters. There are several tools to brute force simple password.