rhd
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So realistically what's the lifespan of this diode running it off a 3.5A driver that's well heatsinked? how many hours of MTTF?
This is not an appropriate question, and you should be very cautious of anyone who pretends to have an answer for you.
You've asked this same question in other threads. The very appropriate response you've received elsewhere is that it's not possible to estimate the lifespan of diodes that are being run outside of spec.
So if you just want someone to guess, you can guess for yourself. Take the estimated lifespan of the diode at datasheet current, if you know it, and pick a random number that's less than that