Always used to mash alu freehubs (I’m a rather hefty bugger) then I got the chance to talk to someone at DT and immediately tried to skewer him about this issue.
His response was to ask what torque I’d done my lockring up to, ‘errrr tight’ was my response.
After pretty much being being told to go away and think about what I’d done I replaced my mangled freehub body and started torqing my cassette up to 40nm as stated on the lockring and, low and behold. No more stuck cassettes.
That freehub is going strong 2 years later, I had the cassette off a few weeks ago and it looked newer then the previous one did after a few rides.