When we want to use the Darlington works as a switch then it is get into a bad situation, the situation maybe like these -- because only the second bjt could works as a transistor switch, but the first bjt is works as two diodes, so the second Vce of njt as Vce2 = Vin - Vbc1= 1.4V-0.7V = 0.7V, W2=Vce2*Ic2=0.7V*3.5A=2.45W, so you can see it why it is getting hot, when the Ic is higher then the Vce also will be higher.Yeah, your right. We have both numbers.
But the 3.3 would explain why the Darlington didn't work either.
I was tested the situation of darlington pair as above, but I didn't test the circuit as TIP120, probably it has a better situation.