> If the FET is not fully on, then its DC resistance will be greater, leading 
> to far greater thermal losses, i.e. it'll get hotter... In an SMPS, its vital 
> that the switching device is either fully on or fully off, and not ever 
> somewhere in its linear region

I was thinking along those lines too - perhaps some flux residue provides a 
little bit of leakage.  Since the FET is high impedance on its gate, a little 
leakage could turn it partially on, leading to heat.  I haven't looked at the 
schematic either, but if the driver circuit doesn't turn the FET off solidly, 
this could happen.

- John

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