not on a car, but my cbr400rr was blowing badly when I bought it so I bought a new set of down pipes. they turned out to be aluminium when they arrived and I had no trouble with them at all, and the bike was never ridden gently.
guy in work has an aluminium rear section on his mg-f and that looks good, never heard him complain about it, and he complains about everything else on the car lol
haven't a clue sorry. my bike exhaust stood up very well to a lot of heat cycling, going from below zero in the morning to running temp and then back down again fairly quicly, no issue at all
That piece, especially the Burns Stainless link, was pretty much bang on the money... poor strength at elevated temps, fatigue issues etc. Other issues are formability* and cost in that ally mandrel bends typically cost more ethan stainless. Less of a deal in the areas where ally stands a chance of surviving but another one not mentioned (or i missed) is that ally is an excellant conductor of heat, heat we really want to keep 'in' the exhaust gases for several reasons
I ran a mid box (~ a foot after the cat) back ally pipe on the daily driver for six months or so- more about being too cheap to buy a replacement and too lazy to make something nice out of stainless rather than a proper experiment i.e. just some pipework cobbled together to get to the back of the car when the origional disintigrated. As the Miata guy the hangers were clamped around the pipe rather than welded to it. Nothing failed, no 'proper' corrosion and ally actually has quite a nice 'sound' to it in that stainless can sound a bit tinny compared to mild steel etc.
* more prone to collapsing than stainless when bending typical exhaust dimensions and even after annealing it the flavours of tube the likes of us have access to (6xxx series only) are far more prone to splitting when expanding it to make slip fits. In short you end up spending more (time or money) to save a few kg and it will have a shorter life, potentially very short if it gets grounded on anything.