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Sure, aluminium cranks can be made reliable. Too bad there are too many bad ones out there.
Steel is actually less susceptible to fatigue, though obviously not immune.
Anyway, I wouldn't mind a good quality track crankset made from steel. -
The reason cranks brake at that point is that the whole pedal-crank interface is a poor design.
I don't think I can explain this any better than Jobst Brandt, so I will just link to his posts and his solution.
https://www.sheldonbrown.com/brandt/breaking-cranks.html
https://yarchive.net/bike/crank_break.htmlAnd no, this has nothing to do with overtightening. The washer also doesn't make much of a difference.
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This kind of failure is due to fatigue so has very little to do with the amount of force applied to the pedals. In fact, those big sprinters with massive legs do not fatigue their cranks. It is the long miles that cause this.
Amateur cyclist, amateur framebuilder :)