Ford Repair: Clogging EGR, egr flow, flow code

Question
2005 Escape 3.0L had rough idle with the EGR flow code p0402 and the pdfe module code as well. found that the EGR valve had been stuck open by a peice of material that was grey in color not carbon, could the cat be be breaking apart internally and will Ford cover it under the warranty. The car has 72,000 miles on it this condition happened three times already which I had to remove the EGR and see a peice of that grey material keeping the valve open

Answer
Don't see a whole lot of the, unless you have codes for the cat converter's odds are they won't although most cats are cover for 8/80. what you are most likely seeing are bits of the cylinder head where the exhaust meets the head from normal deterioration