Output inductor very hot

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It's both.
I need to ask myself simple questions to be able to analyse what I see/hear.
I present these questions hoping that answers come back that I can understand.

To it seems very simple. If there is zero current through the inductor then it can't heat up.
Conversely, if there is current through the inductor then there will be two sets of losses. The core loss and the winding loss.
 
Ideally, a reactive component (inductor or capacitor) stores and releases 100% of the energy driven into it. Of course, in the real world, there are no ideal components.

Think of the inductor as the primary side of a transformer. With no load on the secondary of a transformer, there is 'essentially' no current through the primary. If you load the secondary, then you get a proportional current through the primary. When the inductor's core is lossy, it acts like a secondary winding to some degree. Across that winding there is essentially a resistance. The effective resistance would be very high for low loss cores and lower resistance for higher loss cores.

The current that it takes to heat the core can be very small. That's why I stated that there was essentially no current through the inductor. The current that it would take to heat the inductor due to resistive/copper losses would be MUCH greater.
 
Perry, I contacted Bytemark about these inductors. They were not helpful. He told me engineering could put something together for me, for about $500.00. I've tried to read up on figuring wire diameter and number of turns. But I'm just not getting it. Can you give me some idea on how to make these? Or could I pay you to make them?
 
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