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TPS54239 overheats and self-destructs with 12 volt input

Other Parts Discussed in Thread: TPS54239

This chip is on a step-down circuit board very close to TI's reference design and I'm having sporadic failures of the chip (4 failures in approx 30 boards.)

The boards were assembled by a manufacturer I have used with no previous problems. This failure is serious because boards test okay before I ship and customers are finding the problem when things begin to smoke.

It's possible the solder-pad on the under-side of the chip is not bonding reliably to the circuit board. Any suggestions to fix this problem?

Neil Stanton.