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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
I also have a ROG (Republic Of Gamers) Asus gaming laptop, a maxxed out G50VT with an extreme CPU. When I'm crunching on my CPU and the GPU, the AC adapter is basically completely maxxed out to it's 120 watt rating. It gets very hot. If on carpet it'll get somewhat burning hot. Like you can't touch it for more than a few seconds before beginning to get burned.
It hasn't quit yet, I'm not worried. Not smelling. Genuine AC adapters for older laptops are cheap on Ebay.
But the aftermarket AC adapters aren't as tough, I've gone through a few of those. Not only are the electronics not as resistant to high temperature, but also the cord going to the laptop can, over time, get an open in it so I had to cut off the cord near the tip that goes into the laptop and wire in another tip to the end of the cord.
But genuine AC adapters from Asus (Delta Electronics) are tough, nothing to worry about. Also Flextronics makes genuine adapters.
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.
The battery has a chip in it so the management chip in the laptop won't continually charge the battery at a high rate, at most it would be a continuous trickle charge if the battery is dead. Since it's not accepting a charge, any power going into it would turn to heat. So unless the battery is really warm, that is not a big draw on the AC adapter.
If the battery is old, it won't draw any more power (won't work the AC adapter harder) than a new battery. If anything it would draw less because the internal resistance of the battery is higher.
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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