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This is a fairly old question but I have a rather unique solution. Buy a good laptop fan just for the power brick, it won't provide so much cooling that it will cause damage but will keep it running at a reasonable temprature. I own both an ASUS ROG gaming laptop and an Alienware one as well. Both power supplies have heat issues.
Personaly I use a box fan leaning at an angle against the wall and I have made a support to hold the psu against the fan. This keeps it very cool.
The picture I attached is an older setup in which I used the power cables size to hold it on the fan! (also the psu has feet which fit in the fan notches
The power adapter is getting so hot that you can't touch this, it sounds to me that this might be beyond normal, though some people are more sensitive to temperature than others, and you have an overheating problem.
It could be some strange that you got a bad adapter but how are you cooling your laptop? And are the fans in the laptop running?
If you do have to buy a new charger,
This is a great way to save money in the long run and a good investment as well.
I know personally my power charger gets very hot. As in I don't want to pick it up hot. I also hear a faint crackle. That, I am told, is due to a bad capacitor and will fail soon. This is a 2008 Mac laptop. I am debating on replacing the charger or just get a chromebook since I use a tower at home for most of my work. I am also getting a service battery warning and this is my second battery.
I agree that you can prolong use with some cooling system but it will be something you should handle in the future. Check everything that is mentioned here and see what you can do. And of course back up your system if you your computer does fail while you are working.
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Posted:Aug 14, 2009
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