Most likely., the inductor is exceeding it saturation current. That is the 
point where additional current does not add much magnetic energy, and at 
that point you will see an increase in lost energy (heat).
Try an inductor witrh the same inductance, and a higher Isat rating.

My experience with any sort of switching converter is that they work great 
at low loads, and as you increase the load you see more problems.

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