My mail card went to my friend's address with my name it!!! I had no problem using it - of course it was my name..although sometimes I get one with my first name, which I never use (I only use my middle name) and I've not had a problem..ALSO (this is ridiculous!!) I received an email code with half of my last name (I have a double last name and they dropped the one I use if I use only one...again, had no trouble booking the reservation.
What if you add your brother as the second adult on the reservation and say nothing? I know a name comes up with the pin...hope something works! You can always change the 2nd adult name later and it will not matter then. Wait - your brother should be able to use it - people move!!
As for the email - I was registered on disneyworld.com for a few yrs and received nothing -then during the summer I happened to check my registration and noticed the box to check - I did and within a month I received the email pin #. It was during the time of other discounts but the pin was the best and so far all my pins have been better than ap and equal or better than FL resident rate.