Yes, I have had it happen several times. I had it happen when I foolishly disconnected the battery to "prove" if the alt was charging because of advice I was given by old timers used to generator systems. I had it happen this summer when a loose connection on a starter on a DB990 with Delco 10si let go and fried the alt. I had it happen to a brand new Delco on a Case VAI when an Amish guy I lent it to un hooked the battery while it was running to "test it". Maybe it's not a 99% chance, but for me it's been about that. That's how I got into rebuilding alternators!
And it's not when you try to start it that the problems occur. It's when you're running along and that loose connection lets go and there isn't enough current flow to arc across the gap. Then, IIRC, it's the diode that pops. But hey, if you want to take the chance, have at it. I prefer to avoid having to replace or fix something I don't have to by taking unnecessary risks.
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