I've been using Aquafortis for years without the problem you describe. Are your scales pinned and epoxied? Has the epoxy, if used, had time to cure? Are the pins tight? What kind of heat are you using and for how long? Are you letting the chemical dry before applying heat? Is the maple acclimated to the work area?
Sorry to ask all the questions but all these factors apply to a successful conclusion.
After the scales are pinned and epoxied to the handle area let the epoxy set up at least an hour, sand or file off any squeeze-out. Finish sand the handle with 220 or 320 paper. Apply aquafortis with a swab making sure all wood is covered. Let aquafortis dry completely to a greenish hue. When totally dry turn on the electric range, or if a gas range, place a cast iron griddle over the flame. When the air directly over the burner is too hot to hold your hand in you are ready to start. Holding the knife by the blade with something heat or fireproof, start passing the handle area through the super heated air and watch very carefully the color progression of the maple. Rotate a little with each pass to get even heating all around. When properly done the wood will have the color of dark rust, but no black. You can also use an electric heat gun, but I have found the range method more satisfactory. Finish sand again to smooth and apply finish. I use a varnish/linseed oil/turpentine formula, but most wiping finishes will work. Stains will show grain variation but nothing brings the grain to life like properly applied aquafortis.
Just a couple sparks from this side of the fire.