The process you described was like what the shop my friend used was like. You work in a shop that's certified to repair Audi A8 aluminum cars by any chance? A friend had a Audi A8 that was in a accident. There were only 2-3 shops in the Chicagoland area that were certified to make repairs on them.Other manufacturers have been very successful with using aluminum in their vehicles, Ford has been one of the leaders in the area with their F-150’s. There is aluminum and steel all over that truck. It all goes back to what the coating is they apply to the fasteners and how well it is applied. I have done collision work for 30+ years on high end vehicles, I hate to say it but Chrysler has never had a good reputation with corrosion on all steel vehicles because of their lack of corrosion protection and as of lately their choices of foam in areas that collect moisture. The fact they are now having galvanic corrosion issues isn’t very surprising. They can come up with solutions but the question is will they. And unfortunately most of the shops doing the warranty work have no clue how to properly repair it.
For example a shop takes the door off and sands it down, even if they take a brand new door say and sand it down. If the sandpaper they used was used prior on steel it will embed small particles of steel in the aluminum and the process starts all over again. If they have the sanded area open to the elements and someone else in the shop is sanding or grinding a steel panel in the area and particles fall on the bare aluminum that can be enough to start the process over again. In my shops we have “clean rooms” that are 100% sealed off and ONLY used for aluminum repairs, in the room we have a complete separate set of tools that ONLY get used on aluminum. Any faster that gets removed gets placed in a bag and is only kept until we match up the new replacement, if we run a screw into a part and have to loosen it or remove it for adjustments that screw once again gets replaced no question.