How to determine if the inductor's heating is normal?

Inductor products will inevitably generate heat during use; therefore, don't panic or be alarmed if you encounter an inductor that is heating up! It's important to understand that if the inductor's temperature is below 45 degrees Celsius under normal circumstances, there's no need for concern (note that this refers to typical situations, not environments with special requirements). If the inductor's temperature exceeds 45 degrees Celsius, further analysis is needed to determine the cause of the overheating.
We often find that many components in a circuit exhibit surface heating because heat is generated when current flows through a component during operation. Similarly, heat generation in inductors during operation is unavoidable. However, under normal circumstances, a temperature below 45 degrees Celsius is considered normal. If the inductor's temperature exceeds 45 degrees Celsius, it's necessary to analyze the cause of excessive heating. How can we 'correctly diagnose and address this issue'?
Overheating is a particularly worrisome situation, and this is also true for inductor products. When an inductor overheats, it's understandable to be startled, mainly because we tend to be quite sensitive to inductor heating issues. So why do inductors overheat? And how should we handle inductor overheating? If you don't know, let's find out.

Based on extensive experience from numerous engineering projects, the primary factors contributing to excessive inductor heating are summarized in the following three aspects:
1. Power circuit board design flaws:
Excessive inductor heating can result from circuit design flaws, such as an overloaded circuit or current exceeding the inductor's capacity. This high-load operation causes component heating and can also affect other components. Circuit board designs are usually very strict, so this problem is not typically encountered, but it does exist.
2. Incorrect inductor selection leading to excessive heating:
Mismatched inductor selection results in incompatibility with the entire circuit, leading to inductor overload. When the inductor's DC resistance is high, heat dissipation increases, causing inductor heating and potentially leading to problems such as excessive overheating, circuit board damage, and instability.
3. Inappropriate magnetic core powder formulation:
The magnetic core powder formulation is crucial for inductors. Even inductors of the same model and specifications can exhibit different characteristics depending on the magnetic core powder formulation. However, this issue is easily detected through 100% testing by the component manufacturer before shipment and is generally not encountered by the client.