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> So it seems like the problem is a cooling issue

Not just a cooling issue. It's a MOSFET thermal runaway, as it is being driven to its limit, higher temperature => higher resistance => higher temperature. It can be stopped by cooling it, but the bigger picture is that it is either being driven improperly, or cheap, low power components are used to cut costs without adequate a safety margin.

Laptop audio is ~1-2W of power from 5V rail. Thats at most 500mA going thru this 225 milliohm rdson mosfet.

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