Hi Graham
In fact, it was most likely that Windows 10 "corrected" the file extension. If there is no file association for .aia, the file is examined by Windows 10. Since a .aia file is using zip compression, Windows 10 can decide that it is a zip file, and kindly change the extension for you. Others have had the same issue.
Snag is, App Inventor is not a Desktop program, so you can't associate the .aia files with App Inventor. However, you can associate them with a "neutral" program - I recommend Bandizip, a free file compression program that is compatible with different types. Once associated, Windows 10 will leave the .aia extension alone.