SLinkY

I tried letting things run in real time, but yea, that's not really a solution at all. The problem isn't even exclusively caused by warping either, it manifests during staging as well, as I mentioned. I've never had it during physics warp though, but interestingly it always originates from the same part. For you it's the stack decoupler, for me it's the cubic strut thingy. What I did to work around it is to ignore max temps, do your mission, what ever it is, with a ship that's infinitely hot (like in the gif above. Another thing I've noticed is that infinitely hot solar panels don't generate any power). In my case this was a Mun base, four modules all landing separately (two of the modules are in the gif), joining together, then I went and edited the save file to bring the temps back to within a reasonable range. For me this meant changing "temp" and "tempExt" of the overheated parts from "Infinity" to "103" , which seems to be the ambient temp on the surface of the Mun. I can now warp on the surface and exit warp without any issues. Unless someone has a better way, this is what I'll be doing until it gets patched. *Edit: I should mention that I did a clean install and only reinstalled utility mods, i.e. Kerbal Engineer, docking port alignment, etc

I posted this in another thread, but I'll put this hear so more people can see it and hopefully find some workaround. Exiting warp in Mun SOI with temperature damage off. The heat starts at a cubic octagonal strut and spreads. With the temperature damage on, the strut explodes and the rest of the ship remains undamaged and unheated.

Okay, so I turned on "ignore max temps" and this is what happens. Infinite heat.

I've just discovered the same issue you're having and I've only seen it happen since 1.04 as well. My"explosion by overheating" occurs when I exit rail warp near Mun, this is after an transfer burn from Kerbin. Warping at any time before that works normally. I've got a quicksave just after the transfer burn and it happens to the same part at the same place every time. The other time it happens is during Kerbin ascent, I'd stage some radial boosters way down at the bottom of my ship and the same rover wheel near the top of my ship always explodes due to some phantom overheating. I eventually got the thing into orbit after about 2 hours and 20 attempts... and some luck I guess. I've tried with and without joint reinforcement since with the Mun warp explosion, the ship shakes quite violently before the part explodes, but alas, no difference. This is really frustrating since it's preventing me from completing a biggish contract and so I'm stuck in career mode for now :\ (I suppose I'll just turn part damage off until it's time to land, but that makes me feel like a dirty .....)