I concur a key is required. When alternator goes to full charge it draws quite a bit of mechanical power. I have to wonder why the key did not swap over?
Also measure your battery voltage with the engine running. If this test is not conclusive have the battery tested at a free place. A marginal battery could be making the alternator overcharge too much or requiring a constant heavier duty cycle than normal.
Many alternators are finished off by bad batteries. I also find it strange a counter parts guy would know the sequence of washers etc. Yet not know the key is required. The pulley was never designed to stay in place by surface friction alone.
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