That first picture looks like it's melted, some of the others look like the vehicle might be burning oil, contaminants like oil, coolant, a rich mixture, or misfiring cylinders will cause cats to fail, but that black dark area looks like oil. Interesting there isn't more damage to the front cat. But whatever caused this failure needs to be figured out. When you get it running right, reset the ECM so it can relearn its adaptive fuel strategy, and monitor the Fuel trims and misfire counters, even if the misfires are not bad enough to set a code, they should come up in Mode 6 data. It should be available somewhere in your scan tool, even my 20 year old first OBD2 scan tool had mode 6 data. It's designed for engineers use, but it will show misfires that are not bad enough to set codes. The Cylinder misfires are listed on the 2nd page below, they have changed somewhat, but those are the IDs you will see misfire counts on if nothing else is setting codes.
If you can, with your bore scope, look into the cylinders and see if it looks like the engine is burning oil. The top of the piston will be black with carbon build up heavy, so will the spark plugs. The fuel trims will tell you if its running rich, or if the rear 02 sensor is stuck lean (low voltage below 0.4v will send the ECM rich due to a skewed sensor). Make sure there are no leaks in the exhaust either, Cats can last if they are not overwhelmed with too much Hydrocarbons or CO.
Something else to think about, is changing the oil, after the repair, cleaning the throttle plates and MAF, with this engine not breathing properly, all this stuff is going to have gotten backed up due to the PCV not being able allow crankcase pressures to go somewhere. I'll catch up with you tomorrow if you have any more questions. But I'm glad you got this figured out, we just don't want a new cat to fail.
https://www.2carpros.com/articles/blue-smoke-from-engines-exhaust
https://www.2carpros.com/articles/engine-misfires-or-runs-rough
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Wednesday, November 1st, 2023 AT 2:46 PM