To investigate the inhibitory effect of NH4H2PO4 on the flame propagation of aluminum alloy dust clouds, experiments were conducted in cylindrical vertical ducts. High-speed cameras were employed to capture the explosion flames of aluminum alloy dust clouds under the coupled effect of NH4H2PO4 with different concentrations and particle sizes. The flame propagation behavior of NH4H2PO4/aluminum alloy dust was analyzed, and mathematical models were developed to describe the maximum distance and maximum velocity of NH4H2PO4 inhibition on the flame propagation of aluminum alloy dust clouds. Additionally, the inhibition characteristics of NH4H2PO4 on aluminum alloy dust explosions were studied in a 20 L spherical explosion container, and the thermal decomposition properties of NH4H2PO4 and aluminum alloy particles were investigated using a simultaneous thermal analyzer. Furthermore, the inhibition process of NH4H2PO4 on aluminum alloy dust was explored. The results demonstrate that the concentration of NH4H2PO4 has a greater impact on the inhibition effect on aluminum alloy dust, while the particle size has a smaller influence. Generally, as the concentration of NH4H2PO4 increases, the flame propagation distance and flame development rate decrease, leading to an enhanced inhibitory effect. The addition of NH4H2PO4 slows down the peak pressure of aluminum alloy dust explosions, resulting in a longer duration and smaller peak values of the “double-peak” pressure structure. When the particle size of NH4H2PO4 decreases and the concentration increases, the possibility of the “double-peak” structure decreases, forming a single-peak structure with lower peak values and pressure rise rates. The decomposition temperature of NH4H2PO4 precedes the combustion temperature of aluminum alloy particles. NH4H2PO4 absorbs thermal energy from the reaction system, exerting an inhibitory effect on aluminum alloy dust. The research findings provide valuable references for optimizing explosion suppression parameters and improving powder explosion suppression techniques.