I remind everyone that I have long experience investigating this issue. I have done so with every version of Mail and OSX. There is no doubt that a message with image files and HTML will often be problematic to recipients using Outlook and Outlook Express. The problem is not really Apple's but in Lion they have tried to do something new about it. I disagree, however, with what they have done. In past versions of OSX and Mail you could manage the problem via the use of the Format/Make Plain Text command -- but that generally fails in Lion and Mail 5.x.
In direct communication with Apple staff, after submitting this this as a Bug, I was informed that the behavior I reported is as expected/designed. They further stated that a change was made to so that Mail should encode plain text messages that have inline image attachments as HTML -- thus an acknowledgement that RTF produces HTML. They said the motivation for this change is to work around a long standing problem with Microsoft Exchange Server parsing of multipart mixed MIME messages, wherein that server might change content disposition and cause apparent data loss.
Prompted by an experience with one of three test messages JĂĽrgen sent, I devised a test. In Lion, in Aperture (could just have easily been iPhoto) I chose some images, and clicked to have it compose a new message in Mail. Then in the New Message, I added an empty text file as the final attachment. Then I used the command, Format/Make Plain Text. As in all previous tests, the draft message was changed to look like Plain Text. But unlike all other such tests, when sent, the resulting message remained in Plain Text (which I define as being without HTML.) For control purposes I did the same test again, but without the added empty text file attachment -- as in all other such tests, the result when sent was a message with HTML content, despite having selected to make Plain Text.
So there is something very odd when the outcome of Format/Make Plain Text and subsequent sending can be different depending upon the presence of a trailing empty text file (worked equally well to use a text file containing only Plain Text created in Text Edit). These tests all involved the same SMTP, so that would seem to not be a factor. I am thinking how best to communicate this to proper Apple staff, probably as a follow up to my earlier Bug Report.
Ernie