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TPS54531: Inductor and diode running really hot despite low load

Part Number: TPS54531

Hello,

we have followed the reference design as closely as possible. On the output we are drawing between 700mA and 1.5A of current @ 5V. The inductor and diode are running really hot.

We selected the part, partly because the efficiency graph is flat and gives good efficiency down to the mentioned load when the system is idle.

Is there anything we do wrong?

The inductor is rated at I=5A, Isat=11A and Rdc=28mOhm. So I have a hard time understanding, why the inductor would heat so much at e.g. 1.5A of output current.

Best regards,

Michael